<p>Dicing blades are often used to form microstructures during the machining of difficult-to-cut materials. The impact of dicing process parameters on surface quality is critical during machining, and a better understanding of the influential parameters is desirable. This work employs new dicing blade shapes to evaluate the blade shape-composite interaction influence on the machining of carbon fiber-reinforced plastic (CFRP) composites. The new blade shapes incorporate blunt and flat contact edges to evaluate cutting forces, surface roughness, and morphology of the composite material’s abraded constituents at different cutting depths and fiber cutting angles. The results indicate that the influence of blade shape-composite interaction is crucial for dicing blade machining performance. Flat-end tools can effectively reduce the stress intensity factor than blunt-end tools, resulting in better surface roughness. Flat-end blades give the surface roughness of <InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="170_2025_16285_Article_IEq1.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="20" /> </InlineMediaObject> <EquationSource Format="TEX">${R}_{\text{a}}$</EquationSource> <EquationSource Format="MATHML"><math> <msub> <mi>R</mi> <mtext>a</mtext> </msub> </math></EquationSource> </InlineEquation> between 0.20 and 0.72 µm, and <InlineEquation ID="IEq2"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="170_2025_16285_Article_IEq2.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="20" /> </InlineMediaObject> <EquationSource Format="TEX">${R}_{\text{z}}$</EquationSource> <EquationSource Format="MATHML"><math> <msub> <mi>R</mi> <mtext>z</mtext> </msub> </math></EquationSource> </InlineEquation> is 0.95–4.89 µm, and for blunt-end tools, the range of <InlineEquation ID="IEq3"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="170_2025_16285_Article_IEq1.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="20" /> </InlineMediaObject> <EquationSource Format="TEX">${R}_{\text{a}}$</EquationSource> <EquationSource Format="MATHML"><math> <msub> <mi>R</mi> <mtext>a</mtext> </msub> </math></EquationSource> </InlineEquation> is between 0.64 and 1.49 µm, and <InlineEquation ID="IEq4"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="170_2025_16285_Article_IEq2.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="20" /> </InlineMediaObject> <EquationSource Format="TEX">${R}_{\text{z}}$</EquationSource> <EquationSource Format="MATHML"><math> <msub> <mi>R</mi> <mtext>z</mtext> </msub> </math></EquationSource> </InlineEquation> is 2.63–6.38 µm. Surface morphology reveals that for perpendicular fiber cutting, a flat cutting-edge tool can reduce the influence of the interface on crack propagation, prevent fiber-matrix debonding, and obtain a smooth machining surface at higher cutting depths. When the cutting direction is along the fiber, the flat cutting edge tool interacts with the carbon fiber composite material, causing a certain degree of fiber fracture and leaving behind defined contours on the machined surface. Additionally, response optimization verifies the blade shapes with flat ends as optimal blade shapes for the precise dicing of CFRP composites.</p>

Experimental study on the influence of blade shape-composite interaction for dicing CFRP composites

期刊论文
发表日期：

2025年8月20日

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Ali Riaz,
Zewei Yuan,
Bilal Shabbir Chohan,
Kai Cheng

摘要

Dicing blades are often used to form microstructures during the machining of difficult-to-cut materials. The impact of dicing process parameters on surface quality is critical during machining, and a better understanding of the influential parameters is desirable. This work employs new dicing blade shapes to evaluate the blade shape-composite interaction influence on the machining of carbon fiber-reinforced plastic (CFRP) composites. The new blade shapes incorporate blunt and flat contact edges to evaluate cutting forces, surface roughness, and morphology of the composite material’s abraded constituents at different cutting depths and fiber cutting angles. The results indicate that the influence of blade shape-composite interaction is crucial for dicing blade machining performance. Flat-end tools can effectively reduce the stress intensity factor than blunt-end tools, resulting in better surface roughness. Flat-end blades give the surface roughness of ${R}_{\text{a}}$ $R_{a}$ between 0.20 and 0.72 µm, and ${R}_{\text{z}}$ $R_{z}$ is 0.95–4.89 µm, and for blunt-end tools, the range of ${R}_{\text{a}}$ $R_{a}$ is between 0.64 and 1.49 µm, and ${R}_{\text{z}}$ $R_{z}$ is 2.63–6.38 µm. Surface morphology reveals that for perpendicular fiber cutting, a flat cutting-edge tool can reduce the influence of the interface on crack propagation, prevent fiber-matrix debonding, and obtain a smooth machining surface at higher cutting depths. When the cutting direction is along the fiber, the flat cutting edge tool interacts with the carbon fiber composite material, causing a certain degree of fiber fracture and leaving behind defined contours on the machined surface. Additionally, response optimization verifies the blade shapes with flat ends as optimal blade shapes for the precise dicing of CFRP composites.