Evaluation and mathematical modeling of delamination and cutting forces in milling of carbon fiber reinforced composite (CFRP) materials

Abstract

Nowadays, weight reducing is become possible with composite materials taking place of steel (60-80%) and aluminum (20-50%). Composite materials have become the preferred materials for many engineering applications. However, besides the advantages of composite materials, there are problems in manufacturing. Manufacturing of fiber reinforced composite materials are more difficult than other materials. This situation needs to be very selective in terms of cutting tools. In this study, a unique PCD cutting tool design was devised which is capable of eliminating the encountered difficulties, especially the exfoliation (delamination) problem on laminated/laminar formed composite board during machining carbon fiber reinforced composite (CFRC) materials. With this cutting tools delamination and cutting forces investigated on milling of CFRP materials. 350, 400, 450 m/min cutting speeds and 1270 mm/min constant feed rate were selected as cutting parameters. The first tool were showed the best performance in consequence of the tests. Increasing cutting speed influences the and cutting forces posivitely. Besides, the effective parameters on delamination and cutting forces, were determined according to the obtained ANOVA statistics after the regression analysis.