<p>Carbon fiber-reinforced plastic (CFRP) laminates are widely used for their superior strength-to-weight ratio, but machining them—especially in multidirectional form—remains a technical challenge due to anisotropy and fiber heterogeneity. Machining parameter selection is crucial to improve surface integrity and tool longevity. This study aims to investigate the machinability of multidirectional CFRP laminates in edge milling by analyzing the effect of key process parameters—spindle speed, feed per tooth, and depth of cut—on cutting forces, surface quality, and tool wear. A full factorial experimental design was employed. Cutting forces were measured using a Kistler dynamometer, while surface roughness and machining damage were assessed via 3D optical profilometry. Tool edge degradation was monitored through microscopic cartography techniques. The results show that at short accumulated cutting lengths, increasing spindle speed while decreasing feed per tooth and depth of cut effectively reduces cutting forces, surface roughness, and machining damage. However, at longer cutting lengths, the appearance of tool wear significantly alters machining behavior. The cutting edge radius increases, causing combined effects of tool degradation and process parameters on surface quality. Under the condition of high spindle speed, low feed per tooth, and shallow depth of cut—which initially seems favorable—the surface roughness degrades severely to 6.51&#xa0;µm, with pronounced machining damage and visible micro-chipping at the tool edge. The findings provide a deeper understanding of the interaction between cutting parameters and wear evolution. This insight is critical for selecting machining conditions that balance productivity, tool life, and surface quality in the milling of complex CFRP laminates.</p>

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Analysis of the Machinability of Multidirectional CFRP Laminates

  • Anh-Tuan Dang,
  • Dinh-Ngoc Nguyen

摘要

Carbon fiber-reinforced plastic (CFRP) laminates are widely used for their superior strength-to-weight ratio, but machining them—especially in multidirectional form—remains a technical challenge due to anisotropy and fiber heterogeneity. Machining parameter selection is crucial to improve surface integrity and tool longevity. This study aims to investigate the machinability of multidirectional CFRP laminates in edge milling by analyzing the effect of key process parameters—spindle speed, feed per tooth, and depth of cut—on cutting forces, surface quality, and tool wear. A full factorial experimental design was employed. Cutting forces were measured using a Kistler dynamometer, while surface roughness and machining damage were assessed via 3D optical profilometry. Tool edge degradation was monitored through microscopic cartography techniques. The results show that at short accumulated cutting lengths, increasing spindle speed while decreasing feed per tooth and depth of cut effectively reduces cutting forces, surface roughness, and machining damage. However, at longer cutting lengths, the appearance of tool wear significantly alters machining behavior. The cutting edge radius increases, causing combined effects of tool degradation and process parameters on surface quality. Under the condition of high spindle speed, low feed per tooth, and shallow depth of cut—which initially seems favorable—the surface roughness degrades severely to 6.51 µm, with pronounced machining damage and visible micro-chipping at the tool edge. The findings provide a deeper understanding of the interaction between cutting parameters and wear evolution. This insight is critical for selecting machining conditions that balance productivity, tool life, and surface quality in the milling of complex CFRP laminates.