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Determination of the optimal milling feed direction for unidirectional CFRPs using a predictive cutting-force model

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Abstract

To minimize the cutting force during milling of unidirectional carbon-fiber-reinforced plastics (CFRPs), we present a method that uses a predictive cutting-force model to optimize the feed direction. A CFRP with six different absolute fiber-orientation angles was used to derive specific cutting forces. Cutting force was predicted using regression of the specific cutting force and verified by milling tests, with 2–10-mm radial depths of cut at each fiber-orientation angle. The fiber cutting angle, which significantly affects CFRP cutting characteristics, can easily be changed by varying the feed direction. Therefore, the optimal feed direction is derived by predicting the cutting force in the feed direction in the range 0–180° using the cutting-force model and comparing the cutting forces in all feed directions. The optimal feed direction is expressed by a second-order polynomial function of the radial depth of cut. In the validation of the proposed method, the cutting force and cycle time in the optimal feed direction were reduced by 54% and 53%, respectively. Because only the feed-direction angle is changed, which is a relatively easy adjustment in the milling process, this method efficiently reduces the cutting force in CFRP milling. Also, as a predictive cutting-force model is employed, it is possible to derive the optimal feed direction under various cutting conditions with minimal experimentation.

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Abbreviations

\(\mathrm{\varnothing }\) :

Fiber cutting angle (deg)

\(\theta\) :

Cutting-tool rotation angle (deg)

\({\theta }_{S}\) :

Cutting-tool entry angle (deg)

\({R}_{d}\) :

Radial depth of cut (mm)

\(D\) :

Cutting-tool diameter (mm)

\({\theta }_{E}\) :

Cutting-tool exit angle (deg)

\({\theta }_{c}\) :

Immersion-angle range of the cutting tool (deg)

\(\varphi\) :

Fiber-orientation angle (deg)

\({\varphi }_{a}\) :

Absolute fiber-orientation angle (deg)

\({f}_{d}\) :

Feed direction (deg)

\({F}_{t}, {F}_{r}\) :

Tangential cutting force (N), radial cutting force (N)

\({dF}_{t}, {dF}_{r}\) :

Differential tangential cutting force (N), differential radial cutting force (N)

\({F}_{x}, {F}_{y}\) :

Milling force in x-direction (N), milling force in y-direction (N)

\({K}_{t}, {K}_{r}\) :

Tangential specific cutting force (N/mm2), radial specific cutting force (N/mm2)

\(h\) :

Chip thickness (mm)

\(a\) :

Axial depth of cut (mm)

\(da\) :

Differential axial depth of cut (mm)

\({f}_{t}\) :

Feed rate (mm/rev-tooth)

\(R\) :

Cutting-tool radius (mm)

\(\rho\) :

Run-out error (mm)

\(\lambda\) :

Run-out error angle (deg)

\({F}_{res}\) :

Resultant cutting force (N)

\({N}_{t}\) :

Number of teeth on the cutting tool

\({F}_{sum}\) :

Sum of the resultant cutting forces (N)

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Authors and Affiliations

  1. Advanced Cutting Tool Center, Daegu Mechatronics & Materials Institute, 3, Seongseogongdan-ro, Dalseo-gu, Daegu, 42715, Republic of Korea

    Dong-Gyu Kim & Yun-Chul Jung

  2. School of Mechanical Engineering, Kyungpook National University, 80, Daehak-ro, Buk-gu, Daegu, 41566, Republic of Korea

    Dong-Gyu Kim, Sung-Hwan Kweon & Seung-Han Yang

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  1. Dong-Gyu Kim
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Kim, DG., Jung, YC., Kweon, SH. et al. Determination of the optimal milling feed direction for unidirectional CFRPs using a predictive cutting-force model. Int J Adv Manuf Technol 123, 3571–3585 (2022). https://doi.org/10.1007/s00170-022-10309-w

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