The International Journal of Advanced Manufacturing Technology (2019) 103:4609–4619

https://doi.org/10.1007/s00170-019-03933-6

ORIGINAL ARTICLE

Milling properties of Kevlar 49 fiber composite based on fiber

orientation in cryogenic cooling
Fengbiao Wang 1 & Yongqing Wang 2

Received: 8 January 2019 / Accepted: 21 May 2019 / Published online: 31 May 2019
# Springer-Verlag London Ltd., part of Springer Nature 2019

Abstract
Aramid fiber–reinforced epoxy resin matrix composite is an anisotropic and heterogeneous material. And the machinability is
strongly dependent on the fiber orientation. In this paper, a composite milling model was established based on fiber orientation θ.
Meanwhile, a series of cryogenic cooling milling experiments were carried out to research the influence of fiber orientation on
surface morphology, surface roughness, milling force, and tool wear. The results show that the acute angle milling has more
advantages than the obtuse one. When tool sweeps at about θ = 55°, the maximum milling force can be gotten. And the maximum
shearing action can be reached for latitude fiber at θ = 30°, as well as effectively chip broken for latitude and longitude fibers.
Similarly, with increased θ, the shearing fracture is weakened with insufficient chip breaking, but none affected for longitude
fibers. Besides, it can be predicted that when the cutting speeds are 50, 100, and 150 m/min, as well as fiber orientation 26°, 34°,
and 35°, respectively, the processed surface roughness is 0.93 μm, 0.71 μm, and 0.6 μm. At the same time, tool wear is relatively
serious with θ = 40° with a stable tool wear stage, and the processing effect is not affected. Furthermore, using the bigger cutting
parameters, the better cryogenic cooling milling effect can be obtained at fiber orientation near 30° with less burr defect.

Keywords Fiber-reinforced composite . Fiber orientation . Anisotropic . Cryogenic cooling . Milling properties

1 Introduction
Fiber-reinforced composites include quartz fiber, carbon fiber,
and aramid fiber, and so on. They all had excellent mechanical
properties, high and low temperature resistance, stable physi-
cal and chemical properties, and other advantages. Therefore,
they were widely used in aerospace, national defense and mil-
itary industry, and other fields [1–4]. However, most of these
materials were anisotropic and heterogeneity because of its
different fiber directions with different stress-strains. So the
machining performance was highly dependent on fiber orien-
tation [5, 6], and there were some machining problems such as
large cutting force, low machining efficiency, and serious tool
wear through traditional cutting methods. For example, Zhang
* Fengbiao Wang
wangfb@dlut.edu.cn
1
School of Mechanical Engineering, Shenyang Ligong University,
Shenyang 110159, China
2
School of Mechanical Engineering, Dalian University of Technology,
Dalian 116024, China
et al. [7, 8] divided the cutting area into three areas: chip
formation, extrusion, and rebound in the processing on aramid
fiber–reinforced resin matrix composite. They found that the
lamination direction angle of fiber-reinforced materials had a
great impact on the processing performance of the composites.
Bhatnagar et al. [9] proposed a cutting force prediction model
for fiber-reinforced plastics, and discussed the influence of
cutting direction on cutting performance and the shear
strength in plane of specimens with different fiber orienta-
tions. Su [10] studied the micromechanical behavior of chips
of carbon fiber with different fiber orientations, and implied
that different fiber forces with fiber orientation led to different
chip formation mechanisms. Sheikh-Ahmad [11] discussed
five chip breaking modes of carbon fiber considering different
fiber orientations.
Besides, Su [12] studied the relationship between tool ro-
tation angle and carbon fiber milling quality, and he obtained
that when the angles were 0°, 90°, and 180°, the cutting sur-
face quality was better, but poor for the others. Sahraie [13]
established a cutting force model based on fiber orientation
and calculated the shearing force of a single fiber in an obtuse
cutting. Ben Soussia et al. [14] found that when the fiber
orientation was 0°–90°, the cutting process was mainly the
4610 Int J Adv Manuf Technol (2019) 103:4609–4619

shear fracture failure of workpiece along the fiber direction cooling cutting method. Furthermore, the influence law of
under the action of tool extrusion. And when the fiber orien- fiber orientation on milling performance would be explored
tation was within 90°–180°, the process was the open fracture and clarified.
failure in the fiber/matrix interface, and the fiber was failure
when the fiber bending stress exceeded its bending limit.
Zitoune [15] executed the carbon fiber composite using or-
thogonal cutting process, and they obtained the influence 2 Cutting model based on fiber orientation
law of the fiber orientation on chip formation and fracture.
Meanwhile, they also studied the influence of tool geometry 2.1 Influence of fiber orientation on cutting stress
and deep on cutting force.
Similarly, compared with the traditional dry cutting, the The composite material shows anisotropy and its cutting
composites had great changes about their cutting proper- mechanism is quite different. The cutting removal of this kind
ties because of the changed mechanical properties in cryo- of material is affected by the material properties, but also by
genic. Reed et al. [16] found that the thermal conductivity the fiber orientation. Under different fiber orientations, the
of aramid fiber–reinforced composites was decreased with fibers are subjected to various upward stresses. That results
the decrease of temperature, especially in cryogenic. in different cutting loads on each fiber direction, and it also
Schutz [17] investigated the low temperature mechanical leads to different cutting performances of composite. As
properties of aramid fiber. And the result implied that the shown in Fig. 1, the x-y direction is machining direction, and
thermal expansion rate increased with temperature de- 1-2 is the main direction of single direction fiber layer, and
crease for unidirectional fiber layer. Meanwhile, that was their vector angle is considered the fiber orientation θ.
expansion along the fiber direction and contraction along Meanwhile, x-y coordinate is rotated θ; the 1-2 actual coordi-
the perpendicular fiber direction. At the same time, the nates are obtained. Therefore, the x-y direction stress Formula
thermal expansion coefficient had a downward trend for (1) can be expressed. In fact, the angle of θ is regarded as the
the fiber longitudinal layer, but rise for the lateral fiber angle between the feed direction and fiber layer in the actual
layer. Besides, the elastic modulus and compressive cutting relationship.
strength were slowly increased with lower temperature. 2 3 2 2 32 3
Sohei et al. [18] tested the mechanical properties of ara- σx cos θ sin2 θ −2sinθcosθ σ1
4 σy 5 ¼ 4 sin2 θ cos2 θ 2sinθcosθ 54 σ2 5ð1Þ
mid fiber materials at room temperature, low temperature,
τ xy sinθcosθ −sinθcosθ cos θ−sin2 θ
2 τ 12
and cryogenic environment. And the results showed that
with the decreased in temperature, the tensile strength and
fracture elongation of the material were decreased, but the By matrix transformation, the 1-2 principal stress can be
elastic modulus was increased, especially in cryogenic expressed as
environment with enhanced fiber brittleness. Wang et al.
2 3 2 2 3−1 2 3
[19] carried out the experimental study on aramid fiber– σ1 cos θ sin2 θ −2sinθcosθ σx
reinforced composites and optimized the cutting parame- 4 σ2 5 ¼ 4 sin2 θ cos2 θ 2sinθcosθ 5 4 σy 5
ters. At the same time, they found that the main cutting τ 12 sinθcosθ −sinθcosθ cos2 θ−sin2 θ τ xy
force with brittle cutting was reduced by about 15–20% ð2Þ
comparing with the dry one. The main defects such as
pilling and ablation were significantly inhibited, and the The Formula can be simplified, and it is
surface machining quality and integrity were greatly im- 2 3 2 2 32 3
proved. Furthermore, Xia et al. [20] found that cryogenic σ1 cos θ sin2 θ 2sinθcosθ σx
4 σ2 5 ¼ 4 sin2 θ cos2 θ −2sinθcosθ 54 σy 5 ð3Þ
cooling has an obvious effect on reducing the rounding of
cutting edge and tool outer corner wear. And it also can τ 12 −sinθcosθ sinθcosθ cos2 θ−sin2 θ τ xy
help to enhance the surface integrity in composite drilling
According to the cutting theory, the composite must bear
processing.
the cutting load in the x and y directions in processing, then
In cryogenic environment, the mechanical properties and
there is
microstructure of aramid composite would be changed signif-
8 8
icantly. And the influence of fiber orientation on the cutting < σ1 < σx cos2 θ þ σy sin2 θ þ 2τ xy sinθcosθ
properties would also be changed compared with the tradition- σ ¼ σx sin2 θþ σy cos2 θ−2τ xy sinθcosθ  ð4Þ
: 2 :
al dry cutting. Aiming at aramid fiber–reinforced resin matrix τ 12 σx −σy sinθcosθ þ τ xy cos2 θ−sin2 θ
composite, a milling model based on fiber orientation was
constructed in this paper. Meanwhile, the milling tests consid- At the same time, the shearing stress of rake face τr [11,
ering different fiber orientations were carried out by cryogenic 21–23] can be given by
Int J Adv Manuf Technol (2019) 103:4609–4619 4611

Fig. 1 Cutting model based on (a) (b) (c)

1
fiber orientation angle: milling σ2 σ1
state model (a), coordinate x ω >0 x
relation (b), unit stress analysis (c)
f τ12
y tool τ12
>0 x
R τxy
2
2 σx
y y

   
F y cosϕ−F x sinϕ F x F y sinθcosθ
τ xy ¼ ð5Þ τ 12 ¼ −
αp  αe αe f z αp
 
where ap is the cutting depth (mm), ae is the cutting width F y cosϕ− F x sinϕ  2 
þ cos θ−sin2 θ ð9Þ
(mm), τxy is the shearing stress, and Φ is the shearing angle. αp  αe
Furthermore, the main end milling was expressed in
Fig. 2a, and the milling forces were feed force Fx, vertical When the tool and cutting parameters remain the certain
force Fy, and back force Fz in three intersection directions. values, the shearing stress of composite is affected by the main
In the process, the tool side edge performed part of side mill- cutting force, feed force, and fiber orientation θ. According to
ing (Fig. 2b). the maximum shearing stress theory, the material failure is
The stresses of cutting section in x and y directions can be attributed to the fact that the maximum shearing stress reaches
expressed by the limit value. When the composite material achieved the
maximum shearing stress in cutting, the cutting removal can
Fx be realized. In the specific cutting processing, some special
σx ¼ ð6Þ
αp •αe fiber direction angle can be taken, including acute angle, right
Fy angle, and obtuse angle, such as 0°, 45°, 90°, and 135°, and
σy ¼ ð7Þ the cutting models are shown in Fig. 3.
αp • f z
According to different fiber direction angles, Formula
where fz is feed of each tooth. (9) can be simplified to Formula (10)–(13).
The shearing angle Φ can be represented by the following θ = 0°
Formula.
π F y cosϕ−F x sinϕ
ϕ¼ þ γ 0 −β ð8Þ τ 12 ¼ ð10Þ
4 αp  α e

where γ0 is cutter flank and β is helix angle which is related to

the used tool. θ = 45°
Because the shearing stress plays a major role in cutting, so  
1 Fx Fy
only the change of shearing stress is discussed here, then the τ 12 ¼ − ð11Þ
shearing stress in Formula (4) can be expressed as 2αp αe f z

Fig. 2 Model of milling: ω

cryogenic cooling milling model (a) hollow tool
liquid (b)
(a) and side milling processing
nitrogen
model (b)
f
sample
Fz C B
side milling
Fy
surface ap
end milling
surface ap ae D
ae Fx E A
f
fiber layer
4612 Int J Adv Manuf Technol (2019) 103:4609–4619

Fig. 3 Processing model for chipping

(a) chipping tool shear surface
different fiber orientations: θ = 0° (b)
(a), θ = 45° (b), θ = 90° (c), θ = tool shear surface
135° (d) x =45o
x =0o
y
y re
re workpiece workpiece

chipping
tool
tool shear surface
(c) (d)
x =135o
x =90o
y
y
re
re
workpiece workpiece

θ = 90° edge. Because of the different processing modes, the proc-

essed surface has the different cutting forms with different
F x sinϕ− F y cosϕ
τ 12 ¼ ð12Þ treatment results. In addition, the cutting results are also influ-
αp  α e enced by fiber orientation. Therefore, the material milling pro-
cess can be divided into side cutting and end milling.
θ = 135°
Based on the direction of fiber layer, the milling mode can
 
1 Fx Fy be divided into vertical and parallel layers. Firstly, Fig. 4
τ 12 ¼− − ð13Þ
2αp αe f z shows the vertical layer milling. As being θ < 45°, the surface
quality of vertical milling is all better, and the remaining burr
According to Formula (10)–(13), when the shearing stress is very sparse at side and end milling surface. Meanwhile, the
is positive and reaches the limit value, the composite material workpiece surface can all reach the processing requirements.
is subjected to tensile stress and the removal form is tensile Furthermore, when θ = 30°, the best end and side milling sur-
fracture. But that is extrusion fracture for the negative shearing face can be obtained as well as with the least residual burr. It
stress. At the same time, the obtained shearing stress forms are can be considered that surface quality of vertical milling is less
different with different fiber orientations, which will lead to affected by fiber orientation with less than 45°, so this paper is
different chip breaking forms. not taken it as the key research.
When the fiber orientation is an acute angle for end milling,
the milling surface performance is less changed, and the sur-
2.2 Milling behavior of aramid fiber in cryogenic face quality is better at 45° than 0° (Fig. 5a and b). But it is the
cooling worst surface quality at 90° (Fig. 5c), and the burr removal
effect is also poor at obtuse angle milling (Fig. 5d), which has
Aramid fiber material milling should consider the processing the same result with the literature [7, 24]. Meanwhile, for the
behaviors, and it is included in plane milling of the main side edge milling, the machining quality is the best at 0° angle
cutting edge and the side milling of the secondary cutting relative to 45°. Besides, the cutting effect in right angle and
obtuse angle is still not ideal. Furthermore, an available acute
z
angle between 0° and 45° can reach the requirements of both
x end and side milling surface, so as to obtain the best acute
θ=40o angle cutting.
y
θ=30o
θ=10o
2.2.1 Analysis of side milling force on cutting unit based
end surface side surface on tool spiral angle

Based on the anisotropy of the composite, the milling force is

different following the sweep angle of tool, especially side
Fig. 4 Processing for different fiber orientations along layer direction milling considering spiral angle. Yang et al. [25, 26] combined
Int J Adv Manuf Technol (2019) 103:4609–4619 4613

(a) (b) (c) (d)

workpiece workpiece
workpiece
fiber orientation
fiber orientation feed
fiber n
tatio feed
orien fiber orientation
feed feed
workpiece

Fig. 5 Processing for different fiber orientations along layer direction: θ = 0° (a), θ = 45° (b), θ = 90° (c), θ = 135° (d)

the tool sweep angle and entrance angle, as well as large axial
cutting depth ap > R (milling cutter radius). And then they at
classified the changing process of milling force with the tool dt ¼ ð17Þ
tanβ
rotation angle. The improved conventional milling process
model within the rotation angle of unit tool tooth is shown where there is at = 2Rπ/z, z is the number of tool teeth.
in Fig. 6, as well as the following Formula And the Formula (3) can be deduced that
ap tanβ 2πR
αm ¼ ð14Þ dt ¼ ð18Þ
R ztanβ
where αm was the tool rotation angle in the range of axial In addition, according to the principle of metal cutting, the
effective cutting depth and R is the tool diameter. milling force Fβ can be decomposed into the positive pressure
The projection distance de of tool helix in the axial direc- acting on the rake face and the friction along the cutting sur-
tion can be calculated as Formula (15) in the range of cutting face. Therefore, in side milling, the cutting force Fβ acting on
angle. the cutting unit can be synthesized by the unit positive pres-
αn R sure component Fi.k.t and the unit friction component Fj.k.t, as
de ¼ ð15Þ shown in Fig. 6.
tanβ
According to the specific test, the actual cutting force is
where αn is the entrance angle, and it is equal to θ, and it is affected by ap and ae with ae < R and ap < de. Assuming that
used to control the direction of cutting force, and it can effec- the main tool cutting edge is in the horizontal (latitude) direc-
tively reduce the chip. That has tion, the change of Fβ can be represented by Fig. 7. Firstly, the
tool starts from point B. As the milling length is increased, the
R−ae
αn ¼ arccos ð16Þ cutting force goes up firstly. Because of the unchanged cutting
R length of the DF and the decreased cutting thickness, the cut-
where dt is the axial distance between two adjacent tool spiral ting force slowly rises to point F. When that is started to leave
blades.
The following equation is given: cutting zone
decomposition F
D G
f 1st tool
blade
micro unit 2nd tool
H
G blade
Fβ Fi.k.t ae A B
f E
F Fj.k.t Fβ
Fz F
Fx D D
dt
Fy ap
R
ω C de
fz
αn P O G
O B
αm αt-αm-αn B αm+αn position angle
αm αn
H of tool tip

Fig. 6 Model of milling process Fig. 7 Model of milling force change by scan angle
4614 Int J Adv Manuf Technol (2019) 103:4609–4619

(a) (b)

longitude
within 180°). Figure 8 can be seen as the cutting process of

longitude
fiber
Fx Fnt (Fxy) different fiber orientations. Similarly, the resultant Fxy of the
θ1 F t
feed force F x and the main cutting force F y can be
latitude
decomposed into the normal force Fn and the tangential force
Fn θ 2 Fn Ft.
Fy Fy In details, Fig. 8 shows θ1 between the tangential force and
latitude θ1
tool θ2 Fnt longitude fiber, as well as θ2 with the latitude fiber. As it is
tool Fx 0°°< θ1°< 90°, θ2 = θ1 + 90°; when it is 90°°< θ1°< 180°,
ω Ft (Fxy)
ω θ2 = θ1 − 90°. At the same time, the spiral rising force makes
the latitude fiber have concession phenomenon, which even-
fiber tually leads to the transverse fiber cannot be cut out and form
burrs. Specific as follows:
Fig. 8 Milling model based on fiber orientation: (a) 0°< θ°< 90° and (b) As 0°°< θ1°< 90° (Fig. 8(a)), it is conventional milling, and
90°°< θ°< 180° the latitude fiber is stretched by Fy and sheared by Fx, and the
longitude has the actions of Fx extrusion and Fy shearing.
the cutting area, the cutting force sharply decreases, until it Because Fy is larger, longitude fiber has better chip breaking
completely left the cutting area boundary point G to zero. So effect. Similarly, the milling thickness of each too blade
the cutting force is a process of constant change for the side changes from small to large (Fig. 7). Since the direction of
milling. Due to cutting insufficient of fiber composites, the Fx is opposite to that of feed, the fiber milling method is
burr phenomenon of fiber will often occur. Appropriate and extended by conventional milling.
larger cutting force can effectively prevent insufficient chip When 90°°< θ1°< 180° (Fig. 8(b)), it is climb milling and
breaking defects. However, the greater cutting force is not latitude fiber is squeezed by Fx and sheared by Fx, but it is Fx
better from the actual fiber cutting processing [19]. The larger stretching and Fy shearing for longitude fiber with the rela-
cutting force will lead to higher temperature rise with ablation tively poor chip breaking effect. At the same time, the milling
defects. At the same time, when the cutting force exceeds the thickness of each edge is from large to small, but the average
maximum compressive strength, the fiber weaving formation cutting thickness is large. The direction of Fx is the same as
point will be damaged and the structure will be incomplete. that of feed, and the cutting deformation and cutting force are
Therefore, suitable large cutting force should be used for reduced in squeezed climb milling method.
cutting. The research shows that the anisotropy fiber composite
leads to different cutting performances because of fiber
orientation. At the same time, when it has cutting at acute
2.2.2 Analysis of surface milling model angle and obtuse angle, fiber orientation has a significant
impact on the milling performance along the laminated
Due to the milling, the tool rotation leads to a changed angle surface and vertical surface of fiber. Furthermore, it can
between tool cutting edge and the direction of fiber layer (θ = be known that the effective breaking chip of latitude and
0° − 180°), as long as the effective cutting surface topogra- longitude fibers can be achieved within 45° acute angle.
phies are investigated in a feeding cycle (tool swept slightly Therefore, the optimal fiber orientation can be obtained

Fig. 9 Cryogenic experiment

platform: cryogenic cooling
machine (a) and liquid nitrogen
transport system (b)
Int J Adv Manuf Technol (2019) 103:4609–4619 4615

Table 1 The cutting parameters

Fiber orientation/(°) Cutting width (mm) Cutting speed (m/min) Feed/(mm/r) Cutting depth (mm)

10 6 50 0.07 1.0
20
30 100 1.5
40
50 150 2.0
60 – –

through experimental research, which can be used to
guide conventional dry cutting and cryogenic cooling
milling test.
2.3 Experiments
2.3.1 Experiment material
As the experimental material, the resin-based composite ma-
terial is composed of Kevlar 49 fiber and epoxy resin matrix.
At first, the thin-gauge skin outside of the composite material
was removed, and then some rectangular (50 mm × 50 mm ×
30 mm) workpieces were cut by sawing machine. At last, the
rectangular were numbered.
2.3.2 Manufacturing methods
As illuminated in Fig. 9a, a series of milling experiments were
performed on an independent research and development
three-axis vertical milling machining center equipped with
liquid nitrogen inner-injection function. This machine pos-
sessed the highest spindle speed of 8000 r/min and the table
travel of 300 mm × 300 mm × 200 mm. The hollow tool was
installed in the self-made inner-cooling handle, which was
connected with the machine spindle. The inner-colding verti-
cal milling tool bar was made by the Japanese Kyocera, which
had tool nozzle with a diameter of Φ0.2 mm and 2 TiAlN
carbide film blades (brand for YBG202), and the diameter of
the cutting department was ϕ14mm with helix angle β = 41°.
As illuminated in Fig. 9b, a DPL-175 MP pressurized liq-
uid nitrogen tank (maximum 0.4 MPa pressure and 30 L/h
flowrate) made in Beijing Tianhai Industrial Company.
Furthermore, a self-made liquid nitrogen temperature control
system was employed to inject liquid nitrogen with accurate
flow parameters and to control the liquid nitrogen nozzle tem-
perature T from 77 to 273 K in the cryogenic experiment
platform. According to the closed-loop control of the temper-
ature control system, a certain liquid nitrogen or nitrogen out-
put temperature can be obtained in tool nozzle. At the same
time, through the control system, the room temperature 300 K
can be controlled by the nitrogen rate from another nozzle in
the tank.
Based on the former research results, the detail process
parameters were shown in Table 1. Using single factor analy-
sis method, the cutting parameters were the cutting speed of
vc = 50, 100, and 150 m/min; the feed of f = 0.07 mm/r; and
the milling width of ae = 6 mm, as well as θ = 10°, θ = 20°,
θ = 30°, θ = 40°, θ = 50°, and θ = 60°, respectively.

Table 2 Influence of fiber orientation on cutting surface in cryogenic milling (vc = 100 m/min, ap = 1 mm)

10o 30o 40o 50o

end
milling

side
milling
4616 Int J Adv Manuf Technol (2019) 103:4609–4619

Table 3 The properties of composites at room temperature and low temperature [27, 28]

Fiber direction (°) Temperature (K) Tensile strength (MPa) Shear strength (MPa) Elongation at break (%) Modulus (GPa)

0 293 1530 37 2.7 63

227 1490 – 2.1 68
77 1330 29.3 1.3 84
45 293 125.4 – 6.2 6.4
227 120.8 – 5.7 7.0
77 89 – 1.6 11.9

Meanwhile, the tool blades were packed into a vacuum bag
with serial number after the milling experiment of every group
cutting parameter.
2.3.3 Analysis equipment
An ultra-deep microscope digital microscope (KEYENCE
VHX- 600, Japan) with resolution of 54 million pixels was
used to measure sample surface morphology. A 3D surface
contourgraph (ZYGO New view5022, USA) with the vertical
resolution of 0.1 nm, lateral resolution of 110 nm, scanning
depth of 2–150 microns, and measurement of 0.001 μm was
required to test surface roughness. Besides, a Kisler 9257b
three-phase dynamometer was employed to measure the cut-
ting force at the cutting point. In the processing, the wear loss
of the tool flank was measured by a 40 magnifier tool micro-
scope at 5-min intervals, and the wear pattern of the tool rake
and flank face was observed.
3 Experimental results and analysis
3.1 Milling surface morphology
pits and burrs. But the cutting pits are again increased for θ =
40°. Especially for θ = 50°, it accompanies by initiation and
expansion micro crack. Furthermore, part layer fiber has not
been effectively chip breaking, as well as more burr residual.
Through the former research [4, 19], the tensile strength
and modulus of composite are increased in cryogenic condi-
tion (Tables 3 and 4), and the plasticity and toughness are also
decreased. So the slippage resistance is large during process-
ing, and the shear slippage amplitude is enhanced. And then a
crack is formed in the shear slippage dislocation area, with
bigger expansion speed, the composite is brittle. The mea-
sured data was analyzed further. At 0° < θ1 < 45°, cryogenic
cooling processing method is conventional milling, as shown
in Fig. 8(a). It has a maximum milling force with 55° tool
sweep through Formulas (14) and (16). So milling force is
increasing slightly at 0° < θ1 < 45° (Fig. 8(a)). Similarly, the
effects of Fx shearing and Fy stretching for latitude fiber are all
enhancing, as well as Fx extrusion and Fy shearing for longi-
tude fiber. Under the function of compression stress, shear
stress, and bending stress, fiber has brittle fracture whilst most
of fiber breaking point occurs at the maximum bending stress.
Meanwhile, that leads to longitude matrix be easily cracked
and peeled off whilst cracks and pits are remained, as illustrat-
ed in Table 2. When it is 45° < θ1 < 90° (Fig. 8(b)), latitude

As illuminated Table 2, when the fiber orientation is θ = 10° −

50°, the end milling surface is very clean and complete with 1.8
flush fiber fracture and uniformly covered resin. But for side
50 m/min
milling, when fiber orientation is 10°, parts of the pit and burrs 100 m/min
1.5
appeared on the workpiece surface with the stripped resin and 150 m/min
clear fiber fracture. Similarly, when θ = 30°, the burrs on the
surface are reduced, and the processing surface quality is best, 1.2
and the fiber and resin are loss damage, as well as almost no (26,0.93)

Table 4 Cryogenic composites of 30% fiber and epoxy resin [18, 27]
0.9
* (34,0.71)

Materials Temperature (K) Modulus (GPa) Tensile strength (MPa) 0.6 **

Fiber 295 3.06 125 (35.5,0.6)
77 3.07 161 0.3
0 10 20 30 40 50 60
Epoxy resin 295 3.38 71 o
/( )
77 7.61 86
Fig. 10 Effect of fiber orientation on roughness (ap = 1.0 mm)
Int J Adv Manuf Technol (2019) 103:4609–4619 4617

Fig. 11 Effect of fiber orientation (a) (b)

90
on milling force (vc = 150 m/min): ap=2mm ap=1mm
180
Fy (a) and Fx (b) ap=1.5mm ap=1.5mm
80
ap=1mm ap=2mm
160
70

Fx/N
Fy/N
140
60
120
50
100
40
0 10 20 30 40 50 60 0 10 20 30 40 50 60
o o
fiber orientation /( ) fiber orientation /( )

fiber stretching continues to be strengthened. Although Fx is
increased, after reaching a certain angle, the shearing action
will be decreased due to the change of shear angle (Table 2
illustrates that this angle near θ1 = 50°). At the same time, the
shearing action is little with larger angle, which lead to latitude
fiber having only tensile fracture. And the shear fracture weak-
ened whilst cutting burr remained. However, the longitude
fiber continues to be treated by increasing Fy’s shear action.
When it reaches a certain angle, the Fx’s extrusion action is
decreased. As a result, the longitude fiber shows no obvious
fluffing phenomenon and has fewer surface defects.
compared with the speed change of 50–100 m/min and 100–
150 m/min, the gap trend is obviously decreased. According
to Fig. 10, the minimum roughness may appear between θ =
20° − 30° and θ = 30° − 40°, which is consistent with the op-
timal result in Section 1 with around 45°. At the same time, it
can be predicted that the roughness can be achieved to
0.93 μm, 0.71 μm, and 0.6 μm when the fiber orientation
reaches 26°, 34°, and 35°, respectively, as shown in Fig. 10
(*).
3.3 Milling force analysis

3.2 Surface roughness analysis
As implied in Fig. 10, the surface roughness changes can be
obtained under different cutting speed machining modes with
θ < 60°. The roughness value expresses the obvious phenom-
enon of decreases first and then increases as fiber orientation
increases. When the cutting speed is high, the overall machin-
ing quality is better in cryogenic cooling cutting. But
As illuminated in Fig. 11, the milling force is changed less in
the same cutting depth with no more than 8 N for the bigger
change. They all increased and then decreased. Similarly,
there is less change for the cutting processing with ap =
1 mm. That can be presumed that the fiber orientation has less
effect on small cutting depth. But in different cutting depths,
the maximum main cutting force almost always appeared
closer to θ = 30°, as shown in the dotted line position in

(a) (b) (c)

rake face
rake face rake face
tool edge
tool edge
tool edge

tool nose
tool nose tool nose

(d) (e) tool edge (f)

rake face

tool edge tool nose

tool edge
flank face
flank face
tool nose
tool nose

Fig. 12 Tool wear morphology of cryogenic cooling cutting: θ = 20° rake face (a), θ = 30° rake face (b), θ = 40° rake face (c), θ = 50° rake face (d), θ =
30° flank face (e), and θ = 50° flank face (f)
4618
Fig. 11a. Meanwhile, the maximum feed force almost always
can be found in the vicinity of θ = 40°, as shown in the dotted
line position in Fig. 11b. It can be implied that the optimal
fiber orientation should be between 25° and 35°. This result is
consistent with the optimal cutting effect of vc = 150 m/min
and θ = 35° in Fig. 10. It can be deduced that the relatively
large cutting force is beneficial to the cutting effect.
3.4 Tool wear behavior
After 15 min, cryogenic cooling cutting for each experiment,
the rake, flank, and cutting edge of the tool have been changed
significantly in different fiber orientations. But the tool is still
in the stage of stable wear. It can be concluded that cryogenic
cooling cutting can greatly improve tool life and machining
efficiency. However, the tool wear is still distinguishing in
different fiber orientation conditions. As θ = 20° and 30°
(Fig. 12a and b), the tool wear is smaller. There is a little
bonding material on rake face, as well as a little bit of wear
at the tip (as shown in Fig. 12b, dashed line region at the tip).
As θ = 40°, the wear region of the tip is increased, and the
degree of the main cutting edge is enhanced (Fig. 12c circular
dashed line region). But the secondary cutting edge is worn
less (Fig. 12c ellipse dashed line region). As θ = 50°, there is
more bonding material (Fig. 12d dashed line region). As
shown in Fig. 12e and f, compared with θ = 30°, there are
obvious wear on the tool flank face for θ = 50°, especially
near the cutting edge, and the tool coating has also been
damaged.
4 Conclusions
1. The established model is shown that the fiber orientation
has a significant impact on the milling performance along
the fiber layer surface, but unobvious for vertical layer
surface. Besides, different fiber orientations lead to differ-
ent forms of shearing stress, which will result in different
forms of chip breaking, such as stretch or squeeze forms.
Furthermore, the acute cutting less 45° has more advan-
tages than the obtuse one.
2. For the cutting tool with a sweep angle of 55°, the cutting
force is reached the maximum value. So the force is in-
creasing with θ < 55°. Meanwhile, the latitude fiber is
borne the increasing shearing roles of Fx and stretching
Fy, as well as extrusion Fx and shearing Fy action for the
longitude fiber. When θ = 30°, the maximum shearing
action is achieved for the latitude one. And then the shear-
ing action is weakened, and the shearing insufficient is
appeared with a residual burr, but longitude fiber is not
larger affected.
3. The best surface quality can be obtained with fiber orien-
tation θ = 30° − 40°; the burr defect is less. At the same
Int J Adv Manuf Technol (2019) 103:4609–4619
time, it can be predicted that when the cutting speeds are
50, 100, and 150 m/min, as well as fiber orientation 26°,
34°, and 35°, respectively, the processed surface rough-
ness is 0.93 μm, 0.71 μm, and 0.6 μm. Meanwhile, the
tool wear is relatively larger with θ = 40°, but the tool is
still in a stable wear stage, and its processing effect is not
affected.
Funding information This research was partially supported by the Basic
Science and Research Project of Liaoning Province (No. LG201711), the
Liaoning Key Fund of National Natural Science Fund (No. U1608251),
and the Natural Science Foundation Project of Liaoning Province (No.
20170540787).
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