Journal of Polymer & Composites Original Research
Machining Performance and Tool Wear Behaviour of 3D Carbon Fibre-Reinforced Silicon Carbide Composites
Abstract
3D Cf/SiC composites, consisting of carbon fibers reinforced with silicon carbide are increasingly used in aerospace and defence due to their excellent mechanical properties and high-temperature strength. However, their heterogeneous, anisotropic, and abrasive nature makes them difficult to machine, resulting in accelerated tool degradation and poor surface integrity. This study explores the dry milling performance of 3D Cf/SiC composites using polycrystalline diamond (PCD) and cubic boron nitride (CBN) cutting tools. Initially the wear behaviour of the two tool materials was compared at different machining times. Machining temperature, surface roughness and flank wear were evaluated using thermal imaging and Scanning Electron Microscopy (SEM). PCD demonstrated superior cutting-edge integrity and lower wear than CBN, confirming its suitability for dry machining. PCD milling experiments were subsequently conducted at spindle speeds of 2500, 2750 and 3000 rpm and feed rates of 1800, 2000 and 2200 mm/min, with a constant depth of cut of 0.1 mm. Regression analysis showed that spindle speed had a stronger influence on machining temperature, with the temperature model achieving an R² value of 96.99%, whereas feed rate was the dominant factor affecting surface roughness, with an R² value of 93.51%. Surface roughness increased with increasing feed rate, while higher spindle speed resulted in improved surface finish. Particle Swarm Optimization identified 3000 rpm and 1800 mm/min as the optimum condition, with a predicted minimum surface roughness of 2.323 µm. Flank wear varied with machining conditions, with minimum wear observed at 2750 rpm and 1800 mm/min.
Keywords
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