Cutting force prediction model for machining CFRP with a micro-textured tool considering derivative cutting

Abstract

Carbon fiber reinforced polymer (CFRP) is susceptible to damage, such as face-to-face tearing, burrs, and tool wear, during machining due to excessive cutting forces. To accurately predict the cutting forces during the machining of CFRP using micro-textured tools, this paper proposes a macroscopic mechanical model. Building upon the selection of micro-textured tools from prior work, this study employs micro-textured groove tools with micro-textures parallel to the primary cutting edge. The cutting area is divided into three characteristic regions: the chip region, the extrusion region, and the bounce region. In the chip region, the actual contact area between the rake face and the machined material is reduced due to the presence of micro-textures, and the entry of chips into the texture generates derived cutting forces. Based on the material properties of CFRP, the derived cutting force is calculated by solving the critical shear stress and constructing the cutoff-shear slip line model. Subsequently, a macroscopic mechanical prediction model that accounts for the derived cutting force is established. Finally, the model’s accuracy is verified through orthogonal cutting experiments conducted at various fiber angles. The results demonstrate that the model exhibits high accuracy in predicting cutting forces.