Experimental Design and Optimization of Machining-Induced Cutting Force and Its Effect on Surface Roughness during Milling of Fiber-Reinforced Polymer Composites

Abstract

In this study, we performed milling machining on carbon-epoxy polymer composites and jute-epoxy composites using a CNC vertical machining center. We focused on spindle speed, feed rate, depth of cut, and flute number and analyzed the cutting force and surface roughness. The optimal parameter combination to reduce cutting force in both composites was as follows: S = 600 rpm, FR = 100 mm/min, DOC = 0.25 mm, and FN = 6. The jute-epoxy composites required less cutting force (11.85 N/m2) compared to the carbon-epoxy composites (18.77 N/m2). The average surface roughness of the carbon-epoxy composites (6.685 µm) is higher than that of the jute-epoxy composites (3.08 µm). The type of reinforced material used greatly affects the cutting force and surface roughness during milling.