A main requirement in the field of polymer composites milling with fibre reinforcement is to machine with high quality in one operation (without delamination or burrs). That requires precise selection of cutting tool geometry and cutting conditions. Fibre-reinforced plastics (FRPs) are difficult-to-machine materials due to high abrasivity, relatively low melting point of polymeric matrices and inclination to delamination or large burr formation. This study investigates the main factors influencing the forces, temperature and surface quality in terms of the cutting conditions through ANOVA testing. Machining during this experiment was performed with a polycrystalline diamond (PCD) end mill. Next, the strongest factor with various double-helix cutting tool geometry was compared. The geometric model of the cutting forces was created based on previous measurements as well as a general empirical model of cutting forces, temperature on the machined surface and average delamination length for C/PPS material.

Cutting force models are important for machining processes simulations. This paper presents measurement of cutting forces during C45 (1.0503) carbon steel machining using a coated carbide tool. Various cutting edge geometries and cutting conditions as well as various tool flank wear values were tested. The cutting force coefficients were computed from the experimental data. The results showed that the absolute value of the cutting force coefficients depended on the cutting edge geometry, cutting conditions and tool wear. Additionally, the relative increase in the cutting force coefficients during the tool lifetime was linear and independent of the cutting edge geometries and cutting conditions. The cutting force coefficient models with and without cross components were identified using the linear regression method. Comparison of both models is discussed in the paper

Modelling of cutting forces is important for understanding and simulation of the machining processes. This paper presents cutting force modelling of data obtained from machining of C45 carbon steel with a coated carbide tool. The model is base...