Vibration characteristics and machining performance of carbon fiber reinforced shaft in poor rigidity machining tool system

Abstract Carbon fiber reinforced polymer (CFRP) materials have gained significant attention in the machining industry due to their exceptional strength-to-weight ratio and vibration characteristics. In the poor rigidity machining tool system, such as plunge milling, deep drilling and boring, the large overhanging shaft increases the requirement of chatter stability. In this study, a solution of carbon fiber reinforced shaft was proposed for the poor rigidity machining tool system. The vibration characteristic model was established by theoretical calculation, FE analysis and modal testing. The relationship between fiber arrangement and vibration characteristics was precisely described, and the optimization scheme of fiber reinforcement was proposed considering both the theoretical analysis and procedure technique. The machining performance of the optimal HSS-CFRP shaft was compared with that of the traditional HSS shaft in the same tool system. Main aspects that significantly affect the machining performance were thoroughly evaluated, including tool weight, energy consumption, dynamic characteristics and chatter stability. The effect of fiber reinforcement was fully discussed, which provided a reliable solution for the poor rigidity machining system and other potential applications with large overhanging shaft.