Machining Unidirectional Composites using Single-Point Tools: Analysis of Cutting Forces, Chip Formation and Surface Integrity

The need for high quality machining of composite materials is rising due to the increased utilisation of these materials across several applications. This paper presents experimental findings of orthogonal cutting of unidirectional glass fibre reinforced plastic (UD-GFRP) composites using HSS single-point cutting tools. Key process indicators including cutting forces, chip formation and surface integrity were evaluated. Full factorial design is employed with fibre orientation, depth of cut, cutting speed and rake angle as process control variables. Fibre orientation and depth of cut were found to be the most significant factors affecting the investigated responses. Lower cutting forces and better surface quality were obtained at 0o fibre orientation and lower depth of cut. Cutting at 45o fibre orientation generated extremely damaged surfaces with relatively high average surface roughness values and should be avoided in practical applications.