Rake Angle Effects on Ultrasonic-Assisted Edge Trimming of Multidirectional CFRP Laminates

Machining of CFRP composites is a process frequently accompanied with adverse effects on machined surface. The geometry of the cutting tool, linked primarily to influencing the cutting mechanism, could largely influence the induced damage. An optimum combination of tool material and geometry could improve the cut quality and prolong the tool life. This article investigates the effect of using tools having different rake angles in an ultrasonic-assisted edge trimming operation when cutting multidirectional CFRP laminates. A full-factorial experimental design was adopted to analyse the effect of parameters typically cutting speed, feed rate, rake angle, amplitude, and their interactions on machining performance indicators captured which were the cutting forces, tool wear, chip temperature, and surface roughness. The results showed that UAM mode contributed to the increase in cutting forces, tool wear, and chip temperature compared to conventional mode. On the other hand, UAM mode improved the quality of the machined surface. Additionally, the ultrasonic mode enhances the material removal mechanism using a tool with a negative rake angle.