Performance of Tools Design when Helical Milling on Carbon Fiber Reinforced Plastics (CFRP) Aluminum (Al) Stack

Hole making process is not strictly to the drilling technique where others machining could also influence to the quality in CFRP hole.Therefore, helical milling process becomes as an alternative method to produces bore on CFRP plate thus minimizing the defects. The common defects on CFRP are delamination, splintering and cracking. Meanwhile, if the CFRP stacking together with aluminum plate, burr at exit hole of aluminium plate is produced. Therefore, it is essential to control the critical machining parameters to assure a good quality of the hole. The main objective of this project is to improve the hole quality of CFRP/AL stack in terms of surface roughness using helical milling technique. In addition the cutting force and temperature will be measured as well. There are three levels of cutting speeds; two levels of feed rate and depth per helical path are made accordingly to helical milling characteristics. It was found that all tool design exhibit comparable performance for helical milling process on CFRP/Al stack.