Effect of Cutting Conditions on the Size of Dust Particles Generated During Drilling of Carbon Fiber Reinforced Composite Systems.

The influence of machining parameters on the generation of dust particles during the machining of carbon fiber-reinforced polymer (CFRP) composites remains insufficiently understood. These particles, which stay suspended in the air, pose a serious health risk to operators. This study examined the effects of cutting conditions-specifically cutting speed, feed per tooth, and depth of cut-and the impact of delaminations formed during CFRP drilling on the size, shape, and quantity of hazardous dust particles. Experiments were conducted using a commercially available uncoated cemented carbide cutting tool. The analysis of dust particle size and morphology, as well as the evaluation of delamination, was performed using microscopic and tomographic methods. The results demonstrate that reducing the cutting speed led to a decrease in particle size for the investigated CFRP material. Furthermore, it was observed that tool wear results in the generation of smaller particles. Simultaneous delamination during drilling was found to significantly affect the structural integrity of the composite material.