Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Abstract Fiber-reinforced composites have become the preferred material in fields of aviation and aerospace because their high-strength performance unit weight. The composite components are manufactured by near net-shape only require finishing operations to achieve final dimensional assembly tolerances. Milling grinding arise as choices precision processing. Nevertheless, given laminated, anisotropic, heterogeneous nature, these materials considered difficult-to-machine. As undesirable results challenging breakthroughs, surface damage integrity is a research hotspot with important engineering significance. This review summarizes an up-to-date progress formation mechanisms suppression strategies milling for fiber-reinforced reported literature. First, damage, including delamination, burr, tear, analyzed. Second, mechanisms, covering removal mechanism, thermal mechanical behavior, integrity, discussed. Third, reviewed systematically from aspects advanced cutting tools technologies, ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), tool optimization design. Ultrasonic vibration shows greatest advantage restraining machining force, which can be reduced approximately 60% compared conventional machining. Cryogenic cooling most effective method reduce temperature maximum reduction 60%. MQL its advantages terms reducing friction coefficient, temperature, wear. Finally, gaps future exploration directions prospected, giving researchers opportunity deepen specific explore new area achieving high composites.