Modeling and Experiment of Milling Force under All Fiber Orientation Angles in Slot Milling of Unidirectional CFRP Laminates

Milling force is an important factor in determining the machined surface quality of carbon fibre reinforced polymer (CFRP) in milling process. This paper focuses on the radial force and tangential force under different fibre orientation angles during the milling of unidirectional T800/X850 CFRP laminates. The traditional straight slot milling is replaced by the circumferential slot milling in the experiment and the idea of small scale approximation is applied in analysis of data. Using this method, the milling force under all fibre orientation angles can be obtained approximately by a single experiment and the radial force and tangential force during the milling process can be obtained through mechanical modelling. Through processing experimental data, the coefficients in the theoretical formula of CFRP milling are fitted to get a function about milling force on cut depth, feed and tool rotation angle. And this function can be used to optimise milling parameters and fibre orientation during slot milling. [Submitted 16 January 2017; Accepted 18 December 2017]