Mechanism for changes in cutting forces for down-milling of unidirectional carbon fiber reinforced polymer laminates: Modeling and experimentation

In this study, a new cutting model for the machining of unidirectional CFRP laminates was developed to examine the mechanism for changes in the cutting forces with tool wear. This model is based on Zhang's model and divides the cutting zone into two characteristic deformation regions; chipping...

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Bibliographic Details
Published in:International journal of machine tools & manufacture 2016-01, Vol.100, p.7-13
Main Authors: Maegawa, Satoru, Morikawa, Yuta, Hayakawa, Shinya, Itoigawa, Fumihiro, Nakamura, Takashi
Format: Article
Language:English
Subjects:
Carbon fiber reinforced plastics
Cutting
Cutting parameters
Cutting tools
Cutting wear
Laminates
Polycrystalline diamond tool
Tool wear
Tungsten carbide
Tungsten carbide tool
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Summary:In this study, a new cutting model for the machining of unidirectional CFRP laminates was developed to examine the mechanism for changes in the cutting forces with tool wear. This model is based on Zhang's model and divides the cutting zone into two characteristic deformation regions; chipping and pressing. Furthermore, CFRP milling tests were performed using two kinds of cutting tools: tungsten carbide (WC–Co) and polycrystalline diamond (PCD). Based on the experimental results with the developed cutting model, the net cutting forces to make a cut chip and press CFRP laminates under the flank surface of the tool were quantitatively evaluated. Consequently, it was found that the former does not depend on the progress of the tool wear, but the later increases with tool wear. Additionally, based on the results in this study, a new technique for reducing cutting forces during CFRP machining, which is based on the use of two layer tool that has a wear resistance distribution at around the tool edge was introduced. •A new cutting model for the machining of unidirectional CFRP laminates was developed to estimate the net cutting forces to make a cut chip and press CFRP laminates under the flank surface of the tool.•This model is based on Zhang's model and divides the cutting zone into two characteristic deformation regions; chipping and pressing.•A new technique for reducing cutting forces during CFRP machining was introduced.
ISSN:0890-6955
1879-2170
DOI:10.1016/j.ijmachtools.2015.10.003