Simulation and Experimental Study on Reverse Helical Milling with the Gradual-Removal Reverse Edge Milling Cutter under Ultrasonic-Assisted Condition

As a new machining method, ultrasonic-assisted bi-direction helical milling has obvious advantages in making holes on carbon fiber-reinforced plastics (CFRP). However, cutting edges of the flat-bottomed milling cutter are easy to wear, which may cause severe defects such as burrs and tears in the outlet of the hole. In order to improve the hole-making quality of CFRP, the gradual-removal reverse edge milling cutter was proposed and designed. The finite method models of reverse helical milling CFRP with the flat-bottomed reverse edge milling cutter and the gradual-removal reverse edge milling cutter under an ultrasonic vibration were established, and the comparative cutting experiments of the two cutters were carried out. By comparing the cutting performance of the two milling cutters under the condition of ultrasonic vibration assistance, the cutting mechanism of improving the hole wall quality by the gradual-removal reverse edge milling cutter was studied. The results showed that when the reverse cumulative cutting depth reached about 60 mm, compared with the flat-bottomed reverse edge milling cutter, the gradual-removal reverse edge milling cutter transferred part of the cutting task of the peripheral edge to the end edge, and the wear of the reverse peripheral edges which directly affects the hole quality was effectively alleviated. This mechanism made the cutting state of the peripheral edge dominated by shear failure, which led to the significant improvement of the quality at the outlet of the hole.