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An Experimental Investigation into Trochoidal Milling for High-Quality GFRP Machining
Ondřej Bílek1, Martin Řezníček1, Andrzej Matras2
1Department of Production Engineering, Faculty of Technology, Tomas Bata University in Zlín, Vavrečkova 5669, 76001 Zlín, Czech Republic.
Materials (Basel, Switzerland)
|April 24, 2025
Summary
Trochoidal milling significantly reduces machining time for Glass Fiber Reinforced Polymer (GFRP) by up to 23%. A hybrid approach of trochoidal roughing and conventional finishing optimizes efficiency and accuracy for GFRP components.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Polymer Composites
Background:
- Glass Fiber Reinforced Polymer (GFRP) is a critical composite material in various industries.
- Machining GFRP presents challenges due to its abrasive nature and anisotropic properties.
- Optimizing machining strategies is essential for efficient and high-quality GFRP component production.
Purpose of the Study:
- To compare the effectiveness of trochoidal (adaptive) milling against conventional milling for GFRP.
- To evaluate the impact of different end mill geometries and coatings on machining performance.
- To identify optimal machining parameters for GFRP to enhance efficiency and surface quality.
Main Methods:
- Six coated solid carbide end mills with varying geometries were tested under identical conditions.
- Key performance indicators assessed included cutting forces, surface roughness (Ra), dimensional accuracy, burr formation, chip size, and tool wear.
- Comparative analysis between trochoidal and conventional milling strategies was performed.
Main Results:
- Trochoidal milling achieved cycle times up to 23% faster with higher material removal rates (MRRs).
- Conventional milling offered superior dimensional control and surface finish in specific fiber-sensitive areas.
- A four-tooth cutter with a 10° helix angle and aluminum-oxide coating showed the best overall performance, balancing tool wear and surface finish (Ra as low as 1.36 μm).
- Trochoidal milling effectively managed cutting forces and improved surface quality despite potentially higher RMS cutting forces compared to conventional milling.
Conclusions:
- Trochoidal milling offers significant time savings and improved throughput for GFRP machining when appropriate tooling is used.
- Conventional milling excels in achieving precise dimensional accuracy and smoother surfaces in critical regions.
- A hybrid machining strategy combining trochoidal roughing with conventional finishing presents a promising approach for balancing efficiency and accuracy in GFRP manufacturing.
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