Cutting force analysis considering edge effects in the milling of carbon fiber reinforced polymer composite

Abstract

Machining damage incurred in milling carbon fiber reinforced polymer (CFRP) composite is closely related to the cutting force. However, the dynamic distribution of the cutting force arising from different cutting effects has not been fully investigated. In this study, a new two-region cutting model was used to analyze components of the cutting force resulting from the cutting and edge effects in the milling of CFRP. The friction coefficient was obtained as a function of the fiber cutting angle. The instantaneous magnitudes of the net cutting, pressing and friction forces were identified quantitatively. The variation of different force components and the corresponding specific cutting energies were studied in relation to the cutting mechanisms. The relationship between the cutting forces and machining damage was also investigated. A mechanistic milling force model is proposed. Comparison indicates that the model can produce better prediction of the milling force than the traditional model.