Force coefficient characterization in machining of UD-CFRP using numerical-analytical approach

Abstract

A numerical-analytical approach was utilized to construct a predictive model of cutting force for machining unidirectional carbon fiber reinforced polymer (UD-CFRP) laminates. The force coefficients in the model, which include friction angle, shear plane angle, shear strength, and rebound height, can be characterized by the fiber orientations ranging from 0° to 180°. The accuracy of the model was confirmed through experimental verification. The results indicate good agreement between the predicted and experimental values, with relative errors below 14.8%, except for the thrust force at 90°. Additionally, the study examined the influence of rake angle and flank angle on the cutting force, revealing two critical points in the predicted cutting force curve throughout the fiber orientation. These turning points shifted with changes in the rake angle. For instance, the value of the first critical point changes from 60° to 45° when the rake angle range shifts from [0°, 5°] to [10°, 15°]. This indicates that a larger rake angle facilitated an earlier transformation of chip formation mode, leading to a decrease in cutting force. Furthermore, the cutting force decreased as the rake angle increased between the two turning points. The impact of the flank angle on the cutting force was determined to be minimal, and the turning points’ positions remained consistent as the flank angle increased.