Abstract The material removal mechanism in cutting of carbon fiber reinforced polymer (CFRP) varies with fiber orientation and tool rake angle due to its two-constituent structure. When the fiber orientation is zero degree and tool rake angle is zero or negative, the chip formation process is dominated by the shearing at the interface layer and the buckling of uncut workpiece material. This paper develops a new analytical mechanics model of orthogonal cutting of unidirectional CFRP to predict the forces and chip lengths with shearing-buckling deformation mechanism of the material. A shearing model is developed to determine the maximum resistance force of the workpiece material using energy method. The lengths of machined chips are evaluated based on micro and Euler buckling theories. The tool-workpiece contact force due to tool pressing at the cutting tool edge and flank face is predicted. The developed model reveals the nonlinear relationship between the cutting force and the uncut chip thickness in orthogonal cutting of CFRP. The simulated cutting forces and chip lengths are verified by experimental results at different uncut chip thicknesses and tool rake angles. The developed model determines the fundamental mechanism in orthogonal cutting of CFRP due to its unique anisotropic property.

中文翻译：

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单向碳纤维增强聚合物正交切割的剪屈曲机理

摘要 碳纤维增强聚合物（CFRP）由于其二元结构，切削中的材料去除机制随纤维取向和刀具前角而变化。当纤维取向为零，刀具前角为零或负值时，切屑形成过程以界面层剪切和未切削工件材料的屈曲为主。本文开发了一种新的单向 CFRP 正交切削分析力学模型，以利用材料的剪切-屈曲变形机制来预测力和切屑长度。建立了剪切模型，用能量法确定工件材料的最大阻力。根据微观和欧拉屈曲理论评估加工芯片的长度。由于刀具在切削刀具边缘和后刀面的压力，刀具-工件接触力被预测。开发的模型揭示了 CFRP 正交切削中切削力与未切削切屑厚度之间的非线性关系。模拟的切削力和切屑长度通过不同未切削切屑厚度和刀具前角的实验结果进行验证。由于其独特的各向异性特性，开发的模型确定了 CFRP 正交切割的基本机制。