Influence of Ultrasonic Assistance on Delamination During Machining of Different Composite Materials

A lot of nowadays researches are focused on increasing strength of the components and decreasing their weight, or obtaining unique properties. Composite materials are one of the results of the researches. However, different material properties of matrix and reinforcing material usually cause certain difficulties during conventional machining, such as rapid tool wear and delamination of composite. Therefore, focusing on machinability of this kind of materials is necessary. Scientists have discovered several ways of how to satisfactorily machine different composite materials. Seco Tools Company starts developing a new design of the cutting tools. Researchers of the Stanford University have devised a diamond-like carbon (DLC) coating available to effectively cut matrix as well as reinforce fibres. DMG Mori Company has implemented ultrasonic assistance into machining process and reached enhanced machinability. This article compares conventional milling and ultrasonic assisted milling of the composite materials – glass fibre reinforced plastic (GFRP) and two types of carbon fibre reinforced plastics (CFRP) by using a special designed cutting tool. The results could be applied to determine when ultrasonic assistance is advantageous and what advantages it brings about. The purpose of this study is to determine ways to increase efficiency and productivity of machining different types of composite materials.