Tool life prediction based on cutting forces and surface temperature in edge trimming of multidirectional CFRP composites

Abstract

Fiber reinforced polymers (FRPs) exhibit superior characteristics such as high specific strength, high specific modulus, fatigue strength and endurance. With an increase in the use of composite FRP materials in industries, secondary machining operations of these materials play an important role in final assemblage. This requires adherence of the machined components to the established geometric tolerance, dimensional accuracy, and surface quality. In a previous study, a tool life prediction equation was established based on the process parameters (speed and feed). Since this equation is not satisfactory, this study focuses on economic machining conditions and improved surface quality of the finished component by establishing an equation to predict tool life based on cutting forces and surface temperature in multi directional CFRP machining. The results of experiments show that normal force increases with an increase in feed rate and decreases with an increase in spindle speed and cutting distance. Feed force, axial force and surface temperature increase with an increase in feed rate and cutting distance and decrease with an increase in spindle speed. The tool life prediction equation established in this study based on surface temperature and cutting forces helps the industries to establish an economic machining condition in edge trimming of multidirectional CFRP composites.