Conventional Orthogonal Cutting Machining on Unidirectional Fibre Reinforced Plastics

The results of orthogonal cutting tests on unidirectional carbon and glass fibre reinforced plastics are presented. The specimens were under shape of rectangular plates, circular disks and cylinders with different fibre architectures and a milling machine, a lathe machine and a five-axis high-speed vertical machining centre, were used for the experimental tests. The cutting speed was varied. During the tests, performed at low cutting speed, avoiding thermal effects, and high speed, to investigate about the effect of the cutting velocity on the cut quality, the fibre orientation respect to the cutting direction, the tool rake angle and the depth of cut were varied to investigate their influence on the phenomenon. A high speed steel tool in different geometries, was used. The mechanisms of chip formation and the cutting quality were investigated. A tentative to correlate the mechanisms of chip formation and cutting forces signals was done. Since the anisotropy, the mechanisms of chip formation consists of different failure modes occurring simultaneously and their identification, on the basis of the cutting force evolution, is very complex. Only in particular conditions, the features of cutting forces allow a precise identification of the chip development and detachment. The results indicated that the fibre orientation respect to the cutting direction determines the mechanisms of chip formation and influences the cutting quality. It was noted that for fibre orientation higher than 60°, the quality of the surface was revealed unacceptable. These conclusions were obtained independently of the particular shape of specimen tested and of the speed adopted. © 2017 The Authors. Published by Elsevier B.V.