Title: Investigation Of Optimal Machining Parameters For Fiber-Reinforced Thermoplastic Composite Tooling

Authors: Sucheol Woo, Garam Kim, Yuseop Sim, Jiho Lee, Andrew Sheedy, Varunavi Raghuraman

DOI:

Abstract: Fiber-reinforced composite additive manufacturing is an emerging technology widely used in the production of fiber-reinforced composite parts and manufacturing tools, where the quality of the tool surface is critical for the part's surface finish and the required part demolding force. In the production of additively manufactured composite tools, post-processing through machining is necessary to achieve the required surface finish and dimensional accuracy. However, improper machining parameters can lead to surface defects, such as melted polymer, fiber pullout, and rapid cutting tool wear due to the abrasive nature of the fibers in the workpiece. This study investigates the impact of various machining parameters, surface speed (SFM) and feed rate inches per tooth (IPT), on cutting tool wear and the resulting surface finish quality of additively manufactured fiber-reinforced thermoplastic composite tools. The primary aim is to determine optimal machining parameters that minimize cutting tool wear while maintaining high surface quality for additively manufactured composite tooling. Carbon fiber-reinforced Acrylonitrile Butadiene Styrene (ABS) composites were used in this study. To assess the machining process, temperature, vibration, and sound were measured across a range of machining parameters. A thermal camera was used to monitor the temperatures of the workpiece, cutting tool, and chips throughout the machining process to observe any excessive heat generation. Accelerometers were attached to the spindle to measure vibrations of the Computer Numerical Control (CNC) router during machining. Additionally, sound analysis of the machining operation was conducted using a microphone positioned near the cutting zone to capture audio signals and measure.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 114

Pages: 21

Price: $42.00