Effects of machining parameters on delamination failure in milling of multi-directional CFRP laminate with uncoated carbide cutting tools

Abstract

As one of the main failure mechanisms emerging in the milling of carbon (C)-fiber-reinforced polymer (CFRP) materials, delamination is primarily affected by cutting tool material and geometry, machining parameters and the dynamic loads arising during the machining process. In this study, machinability tests were performed without the use of coolants to examine the effect of machining parameters on multidirectional CFRP composite workpieces, which have a wide application in industries. The tests were applied on a computer numerically controlled vertical processing center at three different cutting speeds (100, 200 and 300 m/min), three different feed rates (0·05, 0·15 and 0·25 mm/tooth) and constant cutting depth (1 mm). Following the tests, the changes in the workpiece were examined in terms of surface roughness, cutting forces, tool wear and delamination failures. The average surface roughness increased with increasing feed rate. Cutting forces also increased with increasing cutting speed, which caused improvements on average surface roughness values. As a machining parameter, feed rate was found to be a determining factor in the machining of CFRP composite materials.