Cutting Parameter Optimization in Milling of Glass Fiber and Carbon Fiber Reinforced Composites to Reduce Cutting Force

Abstract

Abstract Composite materials are often preferred in many engineering applications because of their lightness and high-strength properties. However, in addition to the advantages of composite materials, processing problems exist. The processing of fiber-reinforced composite materials is more complex than other metal materials. The forces that arise during milling cause undesirable results, such as tool wear and energy loss. In this study, the cutting parameter optimization was made by measuring the force during carbon fiber and glass fiber-reinforced epoxy matrix composites milling. Cutting velocity (90, 120, and 150 m/min) and feed per tooth (0.1, 0.15, and 0.2 mm/tooth) were selected as cutting parameters. Experiments were planned according to the Taguchi method with two parameters and three levels. Optimization of the parameters was evaluated using the signal/noise ratio approach. The effectiveness of parameters on results was determined by analysis of variance (ANOVA). Optimum levels were found as 120 m/min for cutting velocity and 0.1 mm/tooth for feed per tooth both glass fiber-reinforced polymer (GFRP) and carbon fiber-reinforced polymer (CFRP) composites. According to the ANOVA results, the contribution rates of the force parameters were 81.05 % for cutting velocity and 15.03 % for feed per tooth in GFRP composites. The contribution rates of the force parameters were 43.69 % for cutting velocity and 46.18 % for feed per tooth in CFRP composites. The surfaces of the milled samples were examined with an optical microscope to investigate the damage. It was observed that the surfaces of CFRP samples had a better surface quality than GFRP samples.