Investigation of chip formation and fracture toughness in orthogonal cutting of UD-CFRP

Abstract

Features of chip formation can inform the mechanism of a machining process. In this paper, a series of orthogonal cutting experiments were carried out on unidirectional carbon fiber reinforced polymer (UD-CFRP) under cutting speed of 0.5m/min. The specially designed orthogonal cutting tools and high-speed camera were used in this paper. Two main factors are found to influence the chip morphology, namely the depth of cut (DOC) and the fiber orientation (angle θ ), and the latter of which plays a more dominant role. Based on the investigation of chip formation, a new approach is proposed for predicting fracture toughness of the newly machined surface and the total energy consumption during CFRP orthogonal cutting is introduced as a function of the surface energy of machined surface, the energy consumed to overcome friction , and the energy for chip fracture. The results show that the proportion of energy spent on tool-chip friction is the greatest, and the proportions of energy spent on creating new surface decrease with the increasing of fiber angle.

Mechanics of material removal when cutting natural fiber reinforced thermoplastic composites

“…Indeed, the chip formation of synthetic fiber composites depends on the matrix nature. For thermoset composites, the removed chip is often discontinuous or powdery [26][27][28][29][30][31][32][33][34][35]. This is inherently related to the mechanical behavior of the thermoset composite during the cutting solicitations.…”

Cutting Performance of Bionic Cutting tools Based on Surface Microstructures of Blood Clams in Dry Cutting of CFRP

“…Cutting tool producers and researchers have developed numerous cutting tools with special geometries for CFRP manufacturers. Li et al [11] presented a detailed experimental investigation of unidirectional bre reinforced polymer (UD-CFRP) orthogonal cutting and chip removal mechanisms in the case of using a specially designed solid tungsten carbide tool. It can be stated that advanced geometry cutting tools are necessary in order to effectively and appropriately machine required quality features when working with CFRP composites.…”

Analysis of Characteristics of Surface Roughness of Machined CFRP Composites

“…1. The influence of fiber cutting angle has been widely investigated by many researchers [6,[10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26] in order to describe chip removal mechanisms in unidirectional CFRP.…”