Uncut fiber analysis using fiber deflection and cutting forces in carbon fiber-reinforced plastics during rotation of the cutting tool

Cutting, milling, and drilling during the manufacture of carbon fiber-reinforced plastics (CFRPs) is an active field of research. It is challenging to analyze cutting characteristics during cutting tool rotation because the chip thickness, fiber cutting angle, and specific cutting force change. Here, we used a mechanical model to study the cutting forces and fiber deflections that develop as the cutting tool rotates during CFRP milling. The fiber and matrix were modeled as a beam, and the cutting force and fiber deflection were analyzed according to the fiber cutting angle. We explored how uncut fiber status and surface roughness were affected. If the fiber deflection caused by transverse cutting forces was not eliminated before the cutting tool rotation angle attained 180°, some fibers were not cut. Serious defects developed when uncut fibers were not generated at certain fiber orientation angles.