The material removal mechanism in orthogonal cutting of woven AFRP

Aramid fiber reinforced plastic (AFRP) has been widely used in the aerospace and defense industries. However, due to its anisotropic and multiphase structure, AFRP is prone to severe machining defects such as fuzzing and tearing. Understanding the AFRP removal mechanism is crucial in controlling the cutting process for improved machining quality. This is the first systematic study reporting the material removal mechanisms of AFRP at various fiber cutting angles (θ) and under different cutting parameters. When θ = 0 °, the material removal process involves peeling of aramid fibers (AF) from the resin matrix caused by the cutting edge. For 0 ° < θ < 90 °, the AF experiences tensile fracture under bending and deflection caused by the cutting edge. θ in the range of 90 ° to 180 ° has led to more severe fiber deformation and interfacical debonding. With increasing depth of cut and decreasing cutting speed, the cutting force increases and the machined surface finish deteriorates. The machined surface shows a distinct smearing feature caused by the cutting edge, with embedded fractured AFRP fiber. This investigation provides a greater insight into the material removal mechanism of AFRP, which may inspire future research in reducing material damages in composite manufacturing.