Investigation of Machining Characteristics and Parameter Optimization for Laser-Assisted Milling of CF/PEEK Composites

Qijia Wang ^1,2,3, Li Fu ⁴, Minghai Wang ^1,2,3

⁰School of Mechatronics Engineering, Shenyang Aerospace University, Shenyang 110136, China.

Micromachines +

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March 6, 2025

View abstract on PubMed

Summary

Laser-assisted milling improves the processing of carbon fiber/polyether ether ketone (CF/PEEK) composites. This method optimizes cutting forces, reduces temperatures, and enhances surface quality, especially at a 0° fiber orientation.

Area Of Science

Materials Science
Manufacturing Engineering
Composite Materials Processing

Background

Carbon fiber/polyether ether ketone (CF/PEEK) composites are vital in aerospace and transportation due to their desirable properties.
Processing challenges arise from CF/PEEK's brittle-ductile two-phase structure.

Purpose Of The Study

To investigate the efficacy of laser-assisted milling for CF/PEEK composites.
To compare laser-assisted milling with conventional milling (CM) in terms of performance and material integrity.

Main Methods

Milling of four CF/PEEK unidirectional plate orientations (0°, 45°, 90°, 135°) using varying laser powers and spindle speeds.
Analysis of cutting forces, temperatures, surface roughness, and damage defects.

Main Results

Optimal machining performance (cutting force, temperature, surface quality) achieved at 0° fiber orientation.
Laser-assisted milling at 90° fiber orientation reduced temperatures by up to 19.8% and forces (Fx, Fy) by up to 20.5% compared to CM.
Significant reduction in surface defects and improved surface roughness observed with laser-assisted milling.

Conclusions

Laser-assisted milling offers superior processing outcomes for CF/PEEK composites compared to conventional methods.
Brittle fracture mechanisms (fiber fracture, pullout, debonding) are prevalent in CF/PEEK machining.
The optimal processing parameters identified are 0° fiber orientation, 400 W laser power, and 4000 rpm spindle speed.

Keywords:

CF/PEEK composites laser-assisted machining milling quantity