Analytical modeling of cutting forces and investigation of the material removal mechanism in milling of HSF/PR composite

Abstract

High silica fiber reinforced phenolic resin composites (HSF/PR composites) have wide applications in aerospace and electronics owing to their excellent ablative and corrosion resistance. However, there are few papers on the cutting mechanism of this material. In this paper, analytical modeling of cutting forces and investigation of the removal mechanism in the cutting of HSF/PR composite are studied. The machining process was studied in two aspects by using experiments: cutting force and surface quality. The cutting force is most affected by the axial depth of cut ap. The surface quality is most affected by the axial depth of cut ap. Removal mechanism presents different patterns depending on the fiber direction. In the meridional direction, the fibers undergo micro-buckling failure due to the compressive stress exceeding their compression limit. In the normal direction, the fibers are sheared off due to the shear stress exceeding the material's shear strength. In the zonal direction, the fibers are affected by different stresses and exhibit various fracture modes. The main defects on the processed surface are holes, cracks, delamination, matrix crack, and fiber pull-out. The research in this paper provides scientific and technical guidance for the processing and application of this material and similar materials.