Abstract
Precision machining of Carbon Fiber Reinforced Polymer (CFRP) is challenging due to its high strength and anisotropic microstructure. This study proposes a specially designed cutting experiment method to understand the influence mechanism of cutting force and surface quality in CFRP high-speed cutting process. The study examines the influence of fiber cutting angle, up/down milling, and machining parameters on the side milling of regular 12-corner unidirectional CFRP samples. Cutting force and surface quality are evaluated to analyze the machining process. The results show that the cutting angle is a key factor influencing milling force and surface quality. For cutting along the fiber, force follows 60° > 30° > 90° > 0°, and against the fiber, it follows 90° > 180° > 150° > 120°. The 90° cutting angle provides optimal surface quality, and cutting against the fiber facilitates material removal. Up-milling can reduce cutting force by 15 %–20 % and surface roughness Sa by up to 25 % compared to down-milling, while improving tool durability. High-speed cutting can reduce surface roughness by at least 35 %. These findings can optimize CFRP machining processes and improve quality results.
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