Study on cutting force and surface roughness during slot milling plain woven CFRP

Abstract Due to the anisotropy and poor heat dissipation of carbon fiber reinforced plastics (CFRP), it is easy to produce high cutting force in the machining process, which makes the machined surface quality worse. This paper studies the effects of spindle speed, feed rate and cutting depth on milling force and surface roughness during slot milling plain-woven CFRP by Taguchi orthogonal experimental design. Convert the instantaneous chip thickness into equivalent cutting area, and the cutting force and surface roughness increase with the increase of equivalent cutting area and decrease with the decrease of equivalent cutting area. The surface material removal mechanism of PCD tool under different equivalent cutting areas is analyzed. The variance analysis of cutting force and surface roughness produced by PCD tool and CVD diamond coated end mill is carried out. It is found that the spindle speed has the most significant effect on cutting force and surface roughness. In addition, it is also found that burrs will occur when the tool rotation angle φ is between 60°-90°and delamination defects occur in the range of 150°-180°.