Investigation of chip formation and fracture toughness in orthogonal cutting of UD-CFRP

Hao Li, Xuda Qin, Gaiyun He, Yan Jin, Dan Sun, Mark Price

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45 Citations (Scopus)
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Features of chip formation can inform the mechanism of a machining process. In this paper, a series of orthogonal cutting experiments were carried out on unidirectional carbon fiber reinforced polymer (UD-CFRP) under cutting speed of 0.5 m/min. The specially designed orthogonal cutting tools and high-speed camera were used in this paper. Two main factors are found to influence the chip morphology, namely the depth of cut (DOC) and the fiber orientation (angle ), and the latter of which plays a more dominant role. Based on the investigation of chip formation, a new approach is proposed for predicting fracture toughness of the newly machined surface and the total energy consumption during CFRP orthogonal cutting is introduced as a function of the surface energy of machined surface, the energy consumed to overcome friction, and the energy for chip fracture. The results show that the proportion of energy spent on tool-chip friction is the greatest, and the proportions of energy spent on creating new surface decrease with the increasing of fiber angle.
Original languageEnglish
Pages (from-to)1079-1088
Number of pages10
JournalInternational Journal of Advanced Manufacturing Technology
Issue number5-8
Early online date30 Jun 2015
Publication statusPublished - Feb 2016


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