Study on Cutting Force Model in Helical Milling of Multi- directional Layup CFRP Composites

doi:10.12068/j.issn.1005-3026.2025.20240071

Abstract

Abstract:

In order to accurately predict cutting forces during helical milling of multi-directional layup carbon fiber reinforced polymer（CFRP） composites， the characteristics of multi-directional CFRP material and the principle of helical milling were analyzed， and the interlayer effects among different fibers of helical milling were considered， the influence of fiber orientation angle on cutting forces was explored. Based on the force conditions in different cutting regions， the microelement cutting force was calculated using the superposition principle， and the cutting force model in helical milling of multi-directional layup composite material was established. Helical milling experiments on multi-directional CFRP were carried out， and the measured cutting force after filtering by the experiment was analyzed. According to the experimental data， the interlayer effect coefficients were calibrated， and experimentally measured cutting forces were compared with the predicted one by the model. The results show that the maximum error of X and Y directional forces is less than 20% and the maximum error of Z directional force is less than 10%， which verifies the correctness of the model.

Key words: multi-directional layup, carbon fiber composites, helical milling, cutting force, interlayer effect

CLC Number:

TH 161

Hai-yan WANG, Qing-chao WANG, Wan-chun YU, Yan FENG. Study on Cutting Force Model in Helical Milling of Multi- directional Layup CFRP Composites[J]. Journal of Northeastern University(Natural Science), 2025, 46(9): 112-118.

Figures/Tables 12

Fig.1 Helical milling process

Fig.2 Fiber cutting angle at 0° fiber orientation

Fig.3 Multi-directional layup CFRP

Fig.4 Cutting state with support

Fig.5 Helical milling of multi-directional CFRP

Fig.6 Force condition on side edge under compression and bending deformation

Fig.7 Helical milling experiment

Table 1 Orthogonal experiment for helical milling

切削参数	水平
切削参数	1	2	3
主轴转速n_rot/(r·min^-1)	4 000	6 000	8 000
轴向切削深度a/(mm·r^-1)	0.1	0.15	0.2
每齿进给量s_t/(mm·齿^-1)	0.04	0.06	0.08

Fig.8 Cutting forces in helical milling of multi-directional CFRPFxFyFzt=At,nrot,st,alxlylz90°/135°. (20)

Table 2 Interlayer effect coefficients

$l 90 x$	$l 90 y$	$l 90 z$	$l 135 x$	$l 135 y$	$l 135 z$
0.93	0.56	0.96	0.74	0.44	0.87

Table 2 Interlayer effect coefficients

$l 90 x$	$l 90 y$	$l 90 z$	$l 135 x$	$l 135 y$	$l 135 z$
0.93	0.56	0.96	0.74	0.44	0.87

Fig.9 Comparison of cutting forces between theoretical and experimental values under different cutting parameters（a）—nrot=8 000 r/min，a=0.15 mm/r，st=0.06 mm/齿；（b）—nrot=4 000 r/min，a=0.15 mm/r，st=0.08 mm/齿.

Table 3 Error analysis of three-directional cutting

误差	1	2	3	4	5
X向力误差	19.19	17.62	19.03	9.75	11.73
Y向力误差	18.81	6.53	9.88	15.04	19.80
Z向力误差	2.53	5.67	2.54	1.39	9.62

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