Abstract
The aim of the research is to optimize the process parameters to attain the desired outcomes of milling the composite materials; glass-fiber reinforced polymers (GFRP), carbon-fiber reinforced polymers (CFRP) and Kevlar-fiber reinforced polymers (KFRP). To enhance the surface integrity and tool life, optimal spindle speed and feed rate for the milling operations are determined. Using the design of experiment techniques, number of experiments are designed, which are replicated and randomized for the accuracy of the results. For the milling of three types of composites, PVD coated carbide milling inserts are mounted in a milling cutter of 16mm. Sides of composite plates are machined (milled) in each experiment, after which the surface roughness is measured at four different locations using high resolution surface roughness gauge. Mean surface roughness is determined for each sample of composite material. It has been observed through the enhanced images of the milling inserts that there is no crater or flank wear were present. Whereas, chipping and damages in the coating occurred at the higher cutting speed and feed rates on the milling inserts.
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