Institut IFT
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Institute of Production Engineering and Photonic Technology
Univ.Prof.DI.Dr. techn.
Friedrich Bleicher

TEC-Lab - Laboratory of Production Engineering
Franz-Grill-Straße 4,
Obj. 221, E311-1
1030 Vienna, Austria


DI Gerhard Wiesinger

+43-(1)-58801-311792
wiesinger@ift.at


Daniel Finkeldei, M.Sc.

+43-(1)-58801-31112
finkeldei@ift.at

Office

Fr. Andrea Kavourmas

Tel.: +43-(0)1-58801-31106
Fax: +43-(0)1-58801-31195
office@ift.at
Homepage: http://www.ift.at

Tool investigation and development

In regular tool examinations, tool manufactureres are invited to participate in this extensive series of tests with standard and prototype tools of their own. On the one hand, the objective is to map the machining of fiber composites by creating a broad database. On the other hand, the variety of cutting tools on the market will be reviewed in terms of their performance in processing of FRP. As an additional incentive, the individual cutting tools are compared with each other and placed in a ranking in opposite to each other.

In direct comparison to the last three tool benchmarks, there is a specific innovation for the procedure and the implementation of the actual tool investigation:

  1. Each participating tool manufacturer can contribute up to five drilling and milling tools to the tool investigation.
  2. The drilling and milling tools are still treated anonymously and published only in terms of their processing results, but not in terms of their tool geometry properties.
  3. The drilling and milling tools are classified and analyzed according to their tool geometry. In this sense, a good tool geometry for the machining of the used fiber composite material is to be found.

The machining process for drilling is as follows:

  1. Machining of 300 holes per tool
  2. Continuous assessment of component quality; Damage is assessed after every 36th hole
    > Quality Index is too high (QI > 2 %) -- process discontinuation
    > Variation of the parameter setting for improvement of the processing quality is allowed
  3. Tool life time test with the best tools; Wear criterion shown in milling investigation below
    > Start of wear measurement after 300 holes

For milling, a tool life time test is carried out for all cutting tools with the following wear criterion:

  1. Flaking of the tool coating
  2. Tool wear land VBmax < 250 µm
  3. Tool wear land VBmean < 150 µm
  4. Notching of the cutting edge VBnotch < 150 µm
  5. Quality Index QI < 2 %
  6. Tool life time T > 20 min

Thereby, a specific change compared to the last three tooling benchmarks has been realized:

  1. Slot milling is the only machining process which will be used in this investigation
  2. In a preliminary investigation, up to five end milling tools will be analyzed in a fundamental parameter study for a variation of the cutting speed and feed
    > Aim: The feed rate should be accelerated considering the produced surface quality
  3. Based on the results of the preliminary investigation (good ratio between feed rate and surface quality), a tool life analysis should be performed with the best end milling tool under the above mentioned wear criteria

The tool investigation 2019/2020 is to be carried out with drilling tools of the diameter range d = 6...7 mm and milling tools of the diameter range d = 6...8 mm. Interested tool manufacturers are welcome to contact Mr. Daniel Finkeldei and complete the registration form.

Tooling benchmark 2013, 2015 and 2018

Altogether, three tooling benchmarks have already been carried out. The aim of these three benchmarks was to compare drilling and milling tools of different tool manufactureres and to contrast them with respect to their produced machining quality in machining of FRP (CFRP, GFRP and AFRP).

The anonymous reports which are intended for the public can be found below: