Delamination or fiber out often occurs when machining carbon fiber reinforced plastics (CFRPs) with conventional cutting tools. Moreover, the tool life is short. As a new machining strategy for peripheral finishing of CFRP plates, an oscillating finish grinding process with a woven metal wire (WMW) tool utilizing plunger pump pulsation is proposed in this study. A WMW tool is a type of core drill, but the tool body is made of woven metal wire. A wire mesh and grinding fluid supplied from the inner side of the wire netting are expected to prevent the clogging of CFRP chips on the tool surface. However, the surface machined by the side face of the WMW tool becomes wavy as the wavy side surface of the WMW tool is copied to the machined surface when the rotating tool moves vertically to the tool axis. To overcome this limitation, a tool oscillation mechanism utilizing plunger pump pulsation action was newly developed and applied for finish grinding. As a result, it was demonstrated that the machined surface roughness of the CFRPs was improved through axial oscillation of the WMW tool.

1. [1] T. Roberts, “Rapid growth forecast for carbon fibre market,” Reinforced Plastics, Vol.51, pp. 10-13, 2007.
2. [2] X. Wang, P. Y. Kwon, C. Sturtevant, D. D. W. Kim, and J. Lantrip, “Tool wear of coated drills in drilling CFRP,” J. of Manufacturing Processes, Vol.15, pp. 127-135, 2013.
3. [3] T. Kaneeda, “CFRP Cutting Mechanism,” Trans. North American Manufacturing Research Institute of SME, Vol.19, pp. 216-221, 1991.
4. [4] T. Tashiro, J. Fujiwara, and N. Asahi, “Cutting Characteristics in End-Milling of CFRP with Diamond-Coated Herringbone Tool,” Int. J. Automation Technol., Vol.10, No.3, pp. 356-363, 2016.
5. [5] M. Hagino and T. Inoue, “Effect of Carbon Fiber Orientation and Helix Angle on CFRP Cutting Characteristics by End-Milling,” Int. J. Automation Technol., Vol.7, No.3, pp. 292-299, 2013.
6. [6] S. Hanasaki, J. Fujiwara, and M. Nomura, “Tool Wear Mechanism in Cutting of CFRP,” Trans. of the Japan Society of Mechanical Engineers, Part C , Vol.60, No.569, pp. 297-302, 1994 (in Japanese).
7. [7] D. Iliescu, D. Gehin, M. E. Gutierrez, and F. Girot, “Modeling and tool wear in drilling of CFRP,” Int. J. of Machine Tools and Manufacture, Vol.50, Issue 2, pp. 204-2130, 2010.
8. [8] A. Koplev, A. Lystrup, and T. Vorm, “The cutting process, chips, and cutting forces in machining CFRP,” Composites, Vol.14, Issue 4, pp. 371-376, 1983.
9. [9] T. Yashiro, T. Ogawa, and H. Sasahara, “Temperature measurement of cutting tool and machined surface layer in milling of CFRP,” Int. J. of Machine Tools and Manufacture, Vol.70, No.7, pp. 63-69, 2013.
10. [10] S. Maegawa, Y. Morikawa, S. Hayakawa, F. Itoigawa, and T. Nakamura, “Effects of Fiber Orientation Direction on Tool-Wear Processes in Down-Milling of Carbon Fiber-Reinforced Plastic Laminates,” Int. J. Automation Technol., Vol.9, No.4, pp. 356-364, 2015.
11. [11] S. L. Soo, I. S. Shyha, T. Barnett, D. K. Aspinwall, and W. M. Sim, “Grinding performance and workpiece integrity when superabrasive edge routing carbon fibre reinforced plastic (CFRP) composites,” CIRP Annals – Manufacturing Technology, Vol.61, No.1, pp. 295-298, 2012.
12. [12] H. Sasahara, T. Kikuma, R. Koyasu, and Y. Yao, “Surface grinding of carbon fiber reinforced plastic (CFRP) with an internal coolant supplied through grinding wheel,” Precision Engineering, Vol.38, pp. 775-782, 2014.
13. [13] K. Ohashi, H. Maeno, R. Fujihara, S. Kubota, M. Yoshikawa, and S. Tsukamoto, “Influence of grinding atmosphere on grinding characteristics of CFRP,” Trans. of the Japan Society of Mechanical Engineers, Part C, Vol.79, No.808, pp. 5068-5078, 2013 (in Japanese).
14. [14] K. Suzuki, R. Koyasu, Y. Ito, Y. Fukuhara, Y. Takeda, M. Matsubara, Y. Yao, K. Nomura, and H. Sasahara, “A newly developed woven metal wire tool with electrodeposited diamond grains and its application for CFRP core drilling,” Proc. 19th ISAAT, pp. 118-123, 2016.
15. [15] Y. Yao, Y. Fuwa, and H. Sasahara, “Development of a device for coolant supply from inside of grinding wheel and its application for profile machining of difficult to grinding materials,” Proc. 4th CIRP Int. Conf. on High Performance Cutting, Vol.1, pp. 417-420, 2010.
16. [16] Z. C. Li, Z. J. Pei, and G. R. Fisher, “Simultaneous double side grinding of silicon wafers: a literature review,” Int. J. of Machine Tools and Manufacture, Vol.46, Nos.12-13, pp. 1449-1458, 2006.
17. [17] H. Sakamoto, M. Touge, and T. Matsuo, “Effect of Quil Motion on Metal Removal Mechanism in Jig Grinding,” Trans. of the Japan Society of Mechanical Engineers, Part C, Vol.61, No.591, pp. 4523-4528, 1995.
18. [18] H. Nakagawa, T. Hirogaki, Y. Iwasaki, T. Hayashi, Y. Kita, and Y. Kakino, “Study on Oscillation Grinding by Numerical Control with a Machining Center,” J. of the Japan Society for Precision Engineering, Vol.68, No.7, pp. 923-927, 2002.
19. [19] Y. Wang, B. Lin, X. Cao, and S. Wang, “An experimental investigation of system matching in ultrasonic vibration assisted grinding for titanium,” J. of Materials Processing Technology, Vol.214, Issue 9, pp. 1871-1878, 2014.
20. [20] A. H. Nor Farah Huda, H. Ascroft, and S. Barnes, “Machinability Study of Ultrasonic Assisted Machining (UAM) of Carbon Fiber Reinforced Plastic (CFRP) with Multifaceted Tool,” Pricedia CIRP, Vol.46, pp. 488-491, 2016.
21. [21] J. J. Shu, C. R. Burrows, and K. A. Edge, “Pressure pulsations in reciprocating pump piping systems Part 1: Modelling,” Proc. of the Institution of Mechanical Engineers Part I, J. of Systems and Control Engineering, Vol.211, No.3, pp. 229-235, 1997.