The anisotropy of fiber-reinforced plastics heavily influences the chip formation and cut quality during machining. Fiber arrangement is found more dominant than the often stressed cutting conditions. The present paper studies the chip formation and constructs an original model for the case of cutting perpendicular to the unidirectional fiber axis. Bending failure controls the chip formation in this process. Beam theory and laminate mechanics are used to establish the correlation between cutting force, chip length and thickness. The proposed model can explain the major trend of the experimental results. Chip separation in thickness due to intrinsic bonding defects and overbent chips due to inhomogeneous local material strength are also found. They are understood based on the current model.

Issue Section:
Research Papers
Topics:
Cutting, Fiber reinforced plastics, Fibers, Anisotropy, Bonding, Euler-Bernoulli beam theory, Failure, Laminates, Separation (Technology), Strength (Materials), Machining
1.
Cheng
S.
,
Wei
X.
, and
Jiang
T.
,
1989
, “
Stress Distribution and Deformation of Adhesive-Bonded Laminated Composite Beams
,”
Journal of Engineering Mechanics
, Vol.
115
, No.
6
, pp.
1150
–
1162
.
2.
Hocheng, H., and Puw, H. Y., 1991, “Milling of Continuous Carbon Fiber Reinforced Plastics,” Processing and Manufacturing of Composite Materials, 112 ASME Winter Annual Meeting, Atlanta, pp. 65–76.
3.
Hocheng
H.
, and
Puw
H. Y.
,
1992
, “
On Drilling Characteristics of Fiber Reinforced Thermoset and Thermoplastics
,”
International Journal Machine Tools & Manufacture
, Vol.
32
, No.
4
, pp.
582
–
592
.
4.
Hocheng
H.
, and
Puw
H. Y.
,
1993
, “
Machinability Test of Carbon Fiber Reinforced Plastics in Milling
,”
Materials and Manufacturing Processes
, Vol.
8
, No.
6
, pp.
717
–
729
.
5.
Inoue
H.
, and
Kawaguchi
I.
,
1990
, “
Study on the Grinding Mechanism of Glass Fiber Reinforced Plastics
,”
Journal of Engineering Materials and Technology
, July, Vol.
112
, pp.
341
–
345
.
6.
Kaneeda, T., 1989, “CFRP Cutting Mechanism,” Proceedings of the 16th North American Manufacturing Research Conference, pp. 216–221.
7.
Koplev, A., 1980, “Cutting of CFRP with Single Edge Tool,” Proc 3rd ICCM, pp. 1597–1605, Paris.
8.
Koplev
A.
,
Lystrup
A.
, and
Vorm
T.
,
1983
, “
The Cutting Process, Chips, and Cutting Forces in Machining CFRP
,”
Composites
, Vol.
14
, pp.
371
–
376
.
9.
Krishnamurthy, R., 1992, “Machining of Polymeric Composites,” Machining of Composite Materials, Proceedings of the Machining of Composite Materials Symposium, Chicago, pp. 139–148.
10.
Sakuma
K.
,
Seto
M.
, and
Taniguchi
M.
,
1985
, “
Tool Wear in Cutting Carbon Fiber-Reinforced Plastics
,”
Bulletin of JSME
, Vol.
28
, No.
245
, November, pp.
2781
–
2788
.
11.
Timoshenko, S., 1955, Strength of Materials, 3rd.
12.
Vinson, J. R., and Sierakowski, R. L., 1986, The Behavior of Structures Composed of Composite Materials, 2nd.
This content is only available via PDF.
Copyright © 1998
 by The American Society of Mechanical Engineers
You do not currently have access to this content.