An analytical approach to cutting force prediction in milling of carbon fiber reinforced polymer laminates

ABSTRACT

A prediction model of cutting force for milling multidirectional laminate of carbon fiber reinforced polymer (CFRP) composites was developed in this article by using an analytical approach. In the predictive model, an equivalent uniform chip thickness was used in the case of orthogonal plane cutting, and the average specific cutting energy was taken as an empirical function of equivalent chip thickness and fiber orientation angle. The parameters in the model were determined by the experimental data. Then, the analytical model of cutting force prediction was validated by the experimental data of multidirectional CFRP laminates, which shows the good reliability of the model established. Furthermore, the cutting force component of flank contact force was correlated with the surface roughness of workpiece and the flank wear of tool in milling UD-CFRP composites. It was found that surface quality as well as flank wear has a co-incident varying trend with the flank contact force, as confirmed by the observations of the machined surfaces and tool wear at different fiber orientations. So, it can be known that low flank contact force be required to reduce surface damage and flank wear.