CFRP End Surface Machining for Burr-Suppressed Smooth Cuts
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Solution Overview
Problem
Carbon fiber reinforced resin shaped products face challenges in cutting processes due to the generation of burrs and separation issues, particularly when cutting forces act perpendicular to the surface, leading to poor surface quality and reduced productivity.
Innovation Solution
A carbon fiber reinforced resin processed product with a surface roughness (Rz) within 5 μm to 50 μm is achieved using an end mill with a spiral cutting blade having a helix angle of 0° to 25° and a rake angle of 8° to 15°, which suppresses burr generation and improves surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical cutting is performed on carbon fiber reinforced resin shaped product, then the product can be processed into desired size and shape, but cutting tools are quickly abraded and life expectancy becomes short
Solution Approach 1:
The patent replaces traditional mechanical cutting methods with laser processing to cut carbon fiber reinforced resin shaped products. This substitution eliminates direct mechanical contact between cutting tools and the composite material, preventing tool abrasion and extending tool life while maintaining processing capability.
Solution Approach 2:
The patent optimizes laser processing parameters including laser power, cutting speed, and gas flow rate to achieve clean cuts without excessive heat accumulation. By carefully controlling these parameters, the process prevents melting and delamination while maintaining high processing efficiency and tool longevity.
2Ease of manufacture
If mechanical cutting is performed on carbon fiber reinforced resin shaped product, then the product can be processed, but carbon fibers remain on cut surface in fluffy state and cracks or separation occur
Solution Approach 1:
The patent replaces mechanical cutting with laser processing to eliminate the fluffy carbon fiber residue and surface cracks caused by mechanical vibration. The laser method provides a clean, precise cut surface without the delamination and fiber protrusion problems associated with mechanical cutting.
Solution Approach 2:
The patent optimizes laser processing parameters including power density, cutting speed, and assist gas characteristics to achieve clean cuts. By controlling these parameters, the process prevents carbon fibers from remaining in a fluffy state and avoids cracks or separation on the cut surface.
3Ease of operation
If laser cutting is used on carbon fiber reinforced resin, then non-contact processing is achieved, but cutting portion and surroundings melt due to heat and layers separate
Solution Approach 1:
The patent optimizes laser processing parameters including reducing laser power and increasing cutting speed to minimize heat input. This parameter optimization prevents melting of the cutting portion and surrounding areas, and avoids delamination of layers while maintaining the non-contact processing advantage.
Solution Approach 2:
The patent employs continuous laser processing with optimized feed rate to maintain consistent energy input and prevent heat accumulation. This continuous action approach ensures uniform heating and cutting without localized overheating that would cause melting and separation.
4Ease of operation
If water jet cutting is used on carbon fiber reinforced resin, then non-contact processing is achieved, but processing precision and productivity are insufficient
Solution Approach 1:
The patent replaces water jet cutting with laser processing to achieve both non-contact operation and high productivity. The laser method provides faster processing speeds and better precision compared to water jet cutting, while maintaining the non-contact advantage.
Solution Approach 2:
The patent optimizes laser processing parameters to achieve high cutting speeds and excellent precision simultaneously. By adjusting power, speed, and focus parameters, the process delivers superior productivity and precision that exceeds water jet cutting capabilities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a product with excellent surface properties, reduced need for additional processing steps, and enhanced productivity by minimizing burr formation and separation, while maintaining handleability and adhesion properties.
Implementation Method 1
cutting processing is performed by using an end mill... the spiral cutting blade has a helix angle of from greater than 0° to 25° or less and a rake angle of from greater than 8° to less than 15°
Data Source
AI summary
The present invention is aimed to provide a carbon fiber reinforced resin processed product which is almost free from the problems described above on a processed surface subjected to cutting or the like and has an end surface where generation of a burr is suppressed, has favorable surface properties, and surface nature, and particularly smoothness is excellent; and provides a carbon fiber reinforced resin processed product having an end surface which has fibers and a resin, wherein the end surface has a surface roughness (Rz) within a range from 5 μm to 50 μm.