Performance of a new hybrid cutting-abrasive tool for the machining of fibre reinforced polymer composites

A new hybrid cutting-abrasive machining tool (turn-grind) is detailed for high-quality machining of fibre reinforced polymer (FRP) composites, comprising single point carbide inserts electroplated with multi-layers of diamond abrasives 120 mu m grain size, to form an abrasive region adjacent to an abrasive-free cutting edge. Experimental data are presented for turning tubes of CFRP and GFRP. The surface quality of workpieces after machining was evaluated through surface roughness measurements and SEM imaging. Cutting-only caused more defects such as delamination and fibre to pull out. Compared with cutting-only, contact and non-contact measurement of surface roughness (Ra) in both axial and radial directions showed an increase for CFRP and GFRP with roundness error reduced to 50%. No significant increase in cutting force was observed.