Modeling of workpiece temperature suppression in high-speed dry milling of UD-CF/PEEK considering heat partition and jet heat transfer

Abstract

High-performance carbon fiber-reinforced polyether-ether-ketone (CF/PEEK) has been gradually applied in aerospace and automobile applications because of its high strength-to-weight ratio and impact resistance. The dry-machining requirement tends to cause the cutting temperature to surpass the glass transition temperature (T_g), leading to poor surface quality, which is the bottleneck for dry milling of CF/PEEK. Temperature suppression has become an important breakthrough in the feasibility of high-speed dry (HSD) milling of CF/PEEK. However, heat partitioning and jet heat transfer mechanisms pose strong challenges for temperature suppression analytical modeling. To address this gap, an innovative temperature suppression analytical model based on heat partitioning and jet heat transfer mechanisms is first developed for suppressing workpiece temperature via the first-time implementation of an air jet cooling process in the HSD milling of UD-CF/PEEK. Then, verification experiments of the HSD milling of UD-CF/PEEK with four fiber orientations are performed for dry and air jet cooling conditions. The chip morphologies are characterized to reveal the formation mechanism and heat-carrying capacity of the chip. The milling force model can obtain the force coefficients and the total cutting heat. The workpiece temperature increase model is validated to elucidate the machined surface temperature evolution and heat partition characteristics. On this basis, an analytical model is verified to predict the workpiece temperature of air jet cooling HSD milled with UD-CF/PEEK with a prediction accuracy greater than 90%. Compared with those under dry conditions, the machined surface temperatures for the four fiber orientations decreased by 30%–50% and were suppressed within the T_g range under air jet cooling conditions, resulting in better surface quality. This work describes a feasible process for the HSD milling of CF/PEEK.

Graphical abstract

Keywords

thermoplastic CF/PEEK / high-speed dry milling / chip formation / heat partition / jet heat transfer / temperature suppression

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