A mechanistic model for cutting force in helical milling of carbon fiber-reinforced polymers

Abstract

Recently, carbon fiber-reinforced polymers (CFRPs) are widely used in the transportation, aerospace, and chemical industries. In order to complete reliable connection with other materials, hole-making performance about CFRP must be systematically studied. While as the typical difficult-to-cut material, tool wear will be very serious in the CFRP cutting process, which will directly influence the change of cutting force, and the larger of the cutting force will lead to the occurrence and propagation of delamination of the holes. In this paper, to accurately predict cutting forces in helical milling of CFRP, a mechanistic cutting forces model considering the fiber cutting angle is established according to cutting principle of helical milling. Based on experimental data, cutting force coefficients are identified according to unidirectional CFRP using average-based method and fitted by response surface methodology (RSM). The results show that the new established force model with the cutting force coefficients can improve the accuracy of the cutting forces, thus achieving an accurate estimate of cutting forces in helical milling of carbon fiber-reinforced polymers.

Al-30Zn Alaşımının Delinmesinde Yüzey Cevap Metodu (YCM) Kullanarak İlerleme Kuvveti ve Yüzey Pürüzlülüğünün Optimizasyonu

“…n ve a0, bi,bij ve bii represent the regression coefficients of the model, , and , descriptive variables, and Y represent the desired machinability output in Equation ( 1) (Chabbi et al, 2017). ANOVA (Analyses of Variance) is used to determine the effect of independent variables on output responses (Meddour et al, 2015;Haiyan and Xuda, 2016). In this study, independent variables were determined as cutting speed and feed (Table 1), while machinability response outputs were determined as thrust force and surface roughness.…”

Machining temperature comparative analysis of end mill and novel tool in orbital drilling of CFRP composite

“…[64], and the coefficients of the cutting edges in the milling part were identified with the method in Ref. [63] and [65]. The average cutting force in steady cutting is used to identify the cutting force coefficient, and the coefficient of ODR tool are listed in Table 4.…”

Geometrical Simulation Model for Milling of Carbon Fiber Reinforced Polymer (CFRP) Composites

“…Sheikh-Ahmad et al [25] have employed Neural Network method to build up the function for calculating cutting coefficients. Haiyan et al [26] have used response surface methodology to fit the curve of cutting coefficients for helical milling with the consider of the cutting depth, spindle speed and feedrate.…”