Innovative technologies for improving the efficiency and machining operating quality for polymer composite materials

An urgent problem for improving the efficiency and machining operation quality for new polymer composite materials (PCM) based on carbon fiber in the operation of rocket and space equipment and aircraft engineering parts is solved in the article. One of the breakthroughs of the Russian domestic engineering is the introduction of wing elements of the new MS-21 civil airliner, the production of noise suppression bodies, compressor blades and other parts of gas turbine engines made of carbon fiber, requiring high-quality and productive machining. Machining operation of these products involves difficulties caused by the requirements of the design documentation to ensure the necessary degree of roughness, soundness of the machined surface and high strength of the finish-machined component. This article presents the results of a study of the application of high-performance technology of sequential blade-abrasive processing of carbon fiber-based PCM products. This article presents the results of a study of the application of high-performance technology of sequential blade-abrasive operation of carbon fiber-based PCM products. The rational geometry of the blade cutting tool for primary machining of the PCM is determined. An adequate empirical mathematical model of cutting modes influence on the surface layer roughness in the milling operation has been developed, as well as rational processing modes have been determined. The results of experimental studies of the abrasion of PCM with rigid grinding wheels made of white electrocorundum, green silicon carbide and elborum are presented. The dependences of the surface layer roughness on the grinding modes are given. According to the research results and the developed mathematical model, the rational characteristics of grinding wheels and processing modes are determined. For the first time, the issues of the influence of machining defects on the strength of PCM are viewed. Comparative tensile and tear strength tests of samples made by traditional edge cutting machining and sequential edge-cutting-abrasive operation are presented. The increase in tensile and tear strength of PCM parts manufactured according to the technology of sequential edge-cutting-abrasive operation by 20.30% compared to traditional edge-cutting operation has been proved.