Work

Study on the influence of tool structure on the gyroscopic milling performance of CFRP/Ti-6Al-4V stacked materials

Year: 2026

Type: article

Abstract: Carbon fiber reinforced polymer (CFRP)/titanium alloy (Ti-6Al-4V) stacked materials have been widely used in the aerospace field due to their excellent mechanical performance. However, owing to the differences in both mechanical and thermal properties between CFRP and Ti-6Al-4V, the machining characteristics of CFRP/Ti-6Al-4V stacked materials are significantly different from those of single-material components. Therefore, selecting appropriate tool structures and machining processes is an effective approach to improving hole quality. This paper proposes a gyroscopic milling process method and conducts comparative experiments on hole-milling using three milling cutters with different corner radii, performed on a self-developed gyroscopic milling actuator. A multi-point offset thermocouple configuration in both axial and radial directions is proposed for cutting temperature measurement. The influence patterns of tool structure and machining parameters on cutting temperature, axial force, and hole-making quality are analyzed. The results indicate that increasing the spindle speed while decreasing the orbital speed and feed rate can effectively reduce the axial force during gyroscopic milling of stacked materials. As the tool corner radius increases, the cutting temperature and axial force demonstrate certain reductions in all machining zones - whether in CFRP, Ti-6Al-4V, or the two-body material machining zone. Compared to the other two milling cutters, the tool with a 2 mm corner radius strengthens the deformation resistance of the residual material at the hole exit zone during machining, thereby achieving a more ideal hole exit quality.

Source: Chinese Journal of Mechanical Engineering

DOI: 10.1016/j.cjme.2026.100236