Milling CFRP using custom-fabricated single-crystal diamond tools

Abstract

This article evaluates the milling performance of custom-fabricated single-crystal diamond (SCD) cutting tools during machining of carbon fiber–reinforced polymer (CFRP) composites. To mitigate the high cost of commercial SCD tools, milling cutters were fabricated by brazing SCD cutting edges with radii below 300 nm. SCD tools with axial rake angles of 0°, 5°, and 10° were assessed under controlled milling conditions. Cutting forces and torques were acquired using a rotary dynamometer. The results show that SCD milling tool geometry and cutting conditions strongly governs cutting mechanics, with a neutral axial rake angle providing better performance in CFRP milling.