Abstract
Machining of carbon fibre reinforced polymer (CFRP) composites is extremely difficult, mainly due to their inhomogeneous and anisotropic properties. Predicting of cutting force during machining of CFRP is also difficult because the machinability properties of the composite are significantly orientation-dependent (fibre and machining directions). The main objective of the present study is to analyse the influence of fibre orientation on cutting force in milling of unidirectional CFRP. Up and down milling experiences were conducted based on a full factorial design. Experimental data were processed by fast Fourier transformation, regression analysis, and graphical adequate analysis. Multiple-order polynomial models were developed in order to minimise cutting force. Experimental results show that fibre orientation angle significantly influences the cutting force; furthermore, it does not have a significant effect on the passive force component, while the radial force component is more sensitive to the fibre orientation at up milling, than at down milling. An optimal condition is recommended for zig-zag milling of unidirectional CFRPs.
Highlights
Carbon fibre–reinforced polymer (CFRP) composite materials are favoured due to their excellent specific mechanical properties in industries where low weight and high strength are required [1, 2]
Diagrams show the main cutting force (F) in the function of machining time. It can be clearly seen in the diagrams that the fibre orientation has a significant effect on the characteristics of cutting force
The maximal cutting force often reaches the 600–800 N values in the case of fibre orientation of 0°, 30°, and 60°; its values are lower at higher fibre orientation angles
Summary
Carbon fibre–reinforced polymer (CFRP) composite materials are favoured due to their excellent specific mechanical properties in industries where low weight and high strength are required [1, 2]. As well as in the automotive, wind turbine, military, sports, and aerospace industries, manufacturers strive to laminate CFRP components in a single operation (moulding and hardening); they often require further processing before they can be used or assembled [4,5,6]. These may include (i) removing material build-up in the dividing plane of the laminating tool, (ii) removing excess material from the flange of the laminating tools, (iii) smoothing the mating surfaces of the laminated composites, and (iv) making. These post-manufacturing needs are met by various machining techniques, like conventional drilling, helical milling, tilted helical milling, wobble milling, side milling, or edge trimming [6, 10,11,12,13]
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