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Investigation on cutting mechanism and micro-damage evolution in orthogonal cutting of T300/USN20000-7901 unidirectional laminates

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Abstract

This paper investigated the cutting behaviors and chip formation in machining of carbon fiber reinforced polymer (CFRP) composites. The single cutting edge and unidirectional (UD) laminates of six different fiber orientations from 0° to 150° with an interval of 30° were employed in the orthogonal cutting test. The effects of fiber cutting angle, cutting speed and cutting depth on cutting mechanism and micro-damage evolution were estimated. Cutting force and thrust force obtained by dynamometer were used to evaluate the interaction between the tool and the workpiece. Subsurface damage was assessed by damage depth and failure mode of microstructure such as fiber and matrix. The machined surface roughness was used to characterize the machined surface quality. The results indicated that the average cutting force at θ > 90° was 7.58 times higher than that at θ < 90° and large deformed fibers below the machined surface existed elasticity recovery in the former case. The cutting speed and cutting depth had the most significant effects on the cutting force at θ = 90° where the fiber bending deformation and fiber kinking keep cutting force at a high level. The micromorphology of machined surface and subsurface revealed four typical cutting mechanisms, namely, interface-debonding, fracture-sliding, shearing-fracture, and bending-fracture in the range of θ = 0 ~ 180°. The variation trend of surface roughness with cutting parameters at θ > 90° is obvious and in consistent with that of cutting force. The most efficient factor on the roughness is found to be the fiber cutting angle accounting for 98.60%, followed by the cutting depth (0.55%) and cutting speed (0.25%). The interaction between the factors is not significant according to the results of ANOVA.

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The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

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Funding

This work is financially supported by National Natural Science Foundation of China (Grant No. 52005259), China Postdoctoral Science Foundation (Grant No. 2022M720939), Anhui Provincial Key Research and Development Plan (Grant No. 202203a05020039) and Jiangsu Key Laboratory of Precision and Micro-Manufacturing Technology Foundation (Grant No. ZAA20003-05). Moreover, the authors would like to acknowledge the editors and the anonymous referees for their insightful comments.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Shengping Zhang, Junshan Hu, Ruihao Kang & Wei Tian

  2. State-Operated Wuhu Machinery Factory, No. 99, Nanyang Road, Wuhu, 241007, China

    Junshan Hu, Shanyong Xuan & Jiali Yu

Authors
  1. Shengping Zhang
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  2. Junshan Hu
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  6. Wei Tian
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Contributions

All authors contributed to the study conception and design. Material preparation was performed by Shengping Zhang and Junshan Hu. Test execution and data collection were completed by Shengping Zhang, Ruihao Kang and Jiali Yu. Data analysis was conducted by Shengping Zhang, Junshan Hu, Shanyong Xuan and Wei Tian. The first draft of the manuscript was written by Shengping Zhang and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Junshan Hu or Wei Tian.

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Zhang, S., Hu, J., Xuan, S. et al. Investigation on cutting mechanism and micro-damage evolution in orthogonal cutting of T300/USN20000-7901 unidirectional laminates. Int J Adv Manuf Technol 126, 4475–4494 (2023). https://doi.org/10.1007/s00170-023-11414-0

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