Adaptive Machining Method for Helical Milling of Carbon Fiber-Reinforced Plastic/Titanium Alloy Stacks Based on Interface Identification

CFRP/Ti stacks composed of carbon fiber-reinforced plastic composites (CFRP) and titanium alloys (Ti) are widely used in aerospace fields. However, in the integrated hole-making process of CFRP/Ti stacks, the machining characteristics of various materials are significantly different, and constant machining parameters cannot simultaneously meet the high-quality machining requirements of two materials. In addition, errors exist between the actual thickness of each material layer and the theoretical value, which causes an impediment to the monitoring of the machining interface and the corresponding adjustment of parameters. An adaptive machining method for the helical milling of CFRP/Ti stacks based on interface identification is proposed in this paper. The machining characteristics of the pneumatic spindle and the interface state in the helical milling of CFRP/Ti stacks are analyzed using self-developed portable helical milling equipment, and a new algorithm for the real-time monitoring of the machining interface position and adaptive adjustment of the machining parameters according to the interface identification result is proposed. Helical milling experiments were carried out, the results show that the proposed method can effectively identify the position of the machining interface with good identification accuracy. Moreover, the proposed parameter-adaptive optimized machining method for CFRP/Ti stacks can significantly improve hole diameter accuracy and machining quality.