Chip Formation and Orthogonal Cutting Optimisation of Unidirectional Carbon Fibre Composites

This study presents a thorough experimental investigation utilising the design of experiments and analysis of variance (ANOVA) to examine the impact of machining process parameters on chip formation mechanisms, machining forces, workpiece surface integrity, and damage resulting from the orthogonal cutting of unidirectional CFRP. The study identified the mechanisms behind chip formation and found it to significantly impact the workpiece orientation of fibre and the tool’s cutting angle, resulting in increased fibre bounceback at larger fibre orientation angles and when using smaller rake angle tools. Increasing the depth of cut and fibre orientation angle results in an increased damage depth, while using higher rake angles reduces it. An analytical model based on response surface analysis for predicting machining forces, damage, surface roughness, and bounceback was also developed. The ANOVA results indicate that fibre orientation is the most significant factor in machining CFRP, while cutting speed is insignificant. Increasing fibre orientation angle and depth leads to deeper damage, while larger tool rake angles reduce damage. Machining workpieces with 0° fibre orientation angle results in the least subsurface damage, and surface roughness is unaffected by the tool rake angle for fibre orientations between 0° to 90° but worsens for angles greater than 90°. Optimisation of cutting parameters was subsequently carried out to improve machined workpiece surface quality and reduce forces. The experimental results showed that negative rake angle and cutting at moderately low speeds (366 mm/min) are the optimal conditions for machining laminates with a fibre angle of θ = 45°. On the other hand, for composite materials with fibre angles of θ = 90° and θ = 135°, it is recommended to use a high positive rake angle and cutting speeds.