Composite Structures 230 (2019) 111441

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Composite Structures
journal homepage: www.elsevier.com/locate/compstruct

Experimental investigation on the cutting mechanism and surface T

generation in orthogonal cutting of UD-CFRP laminates
⁎
Qinglong Ana, , Chongyan Caia, Xiaojiang Caib, Ming Chena
a
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, PR China
b
Shanghai Aerospace Control Technology Institute, Shanghai 201109, PR China

A R T I C LE I N FO A B S T R A C T

Keywords: As carbon fiber reinforced polymer (CFRP) have been widely used as the main material of aeronautic load-
UD-CFRP carrying parts, there are more and more demands of relevant machining work. Due to the significant anisotropy
Fiber orientation angle of CFRPs, defects may easily occur in the machining process. This paper investigated the stress state of carbon
Orthogonal cutting fiber and resin microelements and the formation mechanism of machined surface defects at the micro level, and
Fracture
analyzed the fracture mechanism of carbon fibers and its effects on machined surface morphology at various
Surface morphology
fiber orientation angles θ in the process of CFRP cutting. The results revealed that the cutting mechanism under
parallel fiber cutting conditions is the interface layering separation dominated by in-plane shear stress and the
machined surface is relatively flat and smooth; the cutting mechanism under perpendicular fiber cutting con-
ditions is shear-fracture separation dominated by shear stress and the machined surface is mainly characterized
by regular fiber cross fractures; the cutting mechanism includes the interface layering separation and shear-
fracture separation, and the machined surface is characterized by a regular fluctuating surface composed of fiber
cross fractures with fiber orientation angle 0° < θ < 90°; the cutting mechanism is the bending fracture se-
paration dominated by in-plane bending stress and the machined surface is mainly characterized by pits with
fiber orientation angle 90° < θ < 180°.

1. Introduction removal mechanism of traditional ductile metallic materials. Wang

Carbon fiber reinforced polymer (CFRP) is widely used in aerospace
and automotive industries due to its high specific strength/modulus,
corrosion resistance, thermal shock resistance, low thermal expansion
coefficient and excellent designability [1,2]. Unidirectional carbon
fiber reinforced polymer (UD-CFRP) is one of the main structural ma-
terials for manufacturing advanced aircraft load-carrying parts. To meet
the requirements of dimensional/shape accuracy and surface quality of
final parts, secondary machining such as trimming and drilling is in-
evitable after UD-CFRP molding [3,4]. However, CFRP has significant
inhomogeneity and anisotropy [5,6]. The macro/micro mechanical
properties of the composites depend on the fiber orientation angle. The
mechanism of carbon fiber fracture and defect formation during cutting
is greatly affected by the fiber orientation angle. It is of great sig-
nificance to investigate the fracture behavior of carbon fibers during
CFRP cutting because it directly affects the surface quality and service
life of processed parts.
The removal mode of carbon fibers is brittle fracture caused by
extrusion, shear, tensile and bending, which is different from the shear
et al. [4,7] studied the material removal mechanism of CFRP for the
orthogonal cutting process with fiber orientation angle θ = 0°,
0° < θ < 90°, and 90° ≤ θ < 180°. Wang et al. [5] considered that
material removal mechanism was fiber/resin debonding and the sub-
sequent of bending-induced breakage of fibers in the against fiber
cutting region (90° < θ < 180°), which made the machined surface
seriously damaged. Turki et al. [8] obtained a similar conclusion. Wang
et al. [9] established an analytical model of thermal energy partition
ratio in orthogonal cutting of CFRP based on Hertz contact theory and
heat balance theory. Abena et al. [10] employed zero thickness cohe-
sive elements based on a traction-separation law to simulate the
bonding behavior of fiber/matrix interface, which can overcome the
severe deformation or excessive bonding of fiber/matrix interface.
Madhavan et al. [11] discovered that cutting and thrust forces in-
creased significantly with the increase of θ from 0° to 60°. For
θ = 65°–80°, the dynamic cutting forces changed periodically. Jahromi
et al. [12] established an analytical cutting force model in orthogonal
cutting of CFRP based on the minimum potential energy principle
(MPEP) and representative volume element (RVE). Then they proposed

⁎
Corresponding author.
E-mail address: qlan@sjtu.edu.cn (Q. An).

https://doi.org/10.1016/j.compstruct.2019.111441
Received 9 July 2019; Accepted 14 September 2019
Available online 16 September 2019
0263-8223/ © 2019 Elsevier Ltd. All rights reserved.
Q. An, et al. Composite Structures 230 (2019) 111441

an analytical model to predict the size of surface pits in the against fiber
cutting region according to the mechanism of fiber/resin debonding
and fiber bending fracture, and discovered that the length of fiber/resin
debonding increased with the increase of fiber cutting angle, and the
depth of the surface pit increased first and then decreased with the
increase of fiber orientation angle, and was affected by geometrical
parameters of the tool [13]. Liu et al. [14] analyzed the influence of
fiber orientation angle on the machined surface morphology, and found
that machined surface damage included delamination, tearing and
burrs, fiber/matrix. Rao et al. [15] established a two-dimensional finite
element model for orthogonal cutting process of UD-CFRP. The model
used a cohesive zone to simulate the debonding behavior of fiber-matrix
interface, the attenuation of the elastic modulus of the matrix was also
considered in the model. The fracture criterion of fiber was that the
maximum principal stress reached the tensile strength of the fiber. Fig. 1. Scheme diagram of the fiber orientation angle.
Wang et al. [16] found that surface cavities formed in against fiber
cutting angle caused by fiber/matrix debonding and subsequent
[4,7,23,24]. Fiber orientation angle θ is the angle between cutting
bending/shearing-induced breakage of carbon fibers. Iliescu et al. [17]
speed direction vc and carbon fiber orientation (pointing to the uncut
used a discrete element method to simulate the orthogonal cutting
material layer), as shown in Fig. 1.
process of UD-CFRP, and studied the material removal mechanism at
During the cutting process of CFRP, the material is firstly separated
different fiber orientation angles. The process of chip formation cap-
under the action of tool rake face and edge. Then chips are generated
tured by a high-speed camera was similar to the simulation results, and
and a newly machined surface is formed. During the cutting process of
the cutting forces obtained by numerical simulation was closed to that
CFRP, the machined surface formation involves three mechanisms,
obtained by experiment. Su et al. [18] studied the effect of the relative
namely, cutting formation mechanism, ploughing formation me-
size of cutting depth and tool blunt radius on chip formation me-
chanism and friction formation mechanism. The cutting formation
chanism under different fiber orientation angles in orthogonal cutting.
mechanism indicates the machined surface is directly formed by the
An et al. [19] studied the influence of tool rake angle, flank angle and
section of the cut carbon fibers, where the fracture mode of carbon
blunt radius on cutting force during orthogonal cutting of CFRP. Ex-
fibers determines the properties of the machined surface. The ploughing
perimental results showed that a large rake angle was advantageous to
formation mechanism mainly refers to the influence layer of metal-like
the separation of chips and cutting force reduction. Flank angle α = 15°
plastic deformation in the machined surface layer of workpiece mate-
was beneficial to reduce the influence of material elasticity recovery on
rials including carbon fibers and resins under the push of cutting tools.
tool wear. Qi et al. [20] obtained the deflection function of RVE which
That is to say, the plastic deformation of carbon fibers occurs with the
consisted of a single fiber and a surrounding matrix based on the MPEP.
resin matrix in a very small depth, resulting in ploughing-like surface
According to the deflection function, the critical cutting force leading to
layer. The friction formation mechanism is that the processing elasticity
RVE fracture was obtained, then they established a theoretical force
of CFRP material has a large recovery, and it is easy to form strong
model for orthogonal cutting of UD-CFRP for 0°–90° fiber orientation
friction with the tool flank face, resulting in the impact on the machined
angle. Based on the beam on elasticity foundation theory and MPEP,
surface. The machined surface is formed by the combined action of
Chen et al. [21] established a theoretical model of cutting force for
these three surface formation mechanisms. Fiber orientation angle θ is
orthogonal cutting of UD-CFRP at fiber cutting angle of 0°, 0°–90° and
an important factor influencing the action form and action degree of
90°–180°, respectively. Voss et al. [22] sub-divide the fiber cutting
these three surface formation mechanisms.
angle into four independent sub-models: (1) θ = 0°/180°, (2)
In the cutting process, the fiber orientation angle continuously
15° ≤ θ ≤ 75°, (3) θ = 90° and (4) 105°≤θ ≤ 165°, based on MPEP and
varies from 0° to 180°. Therefore, distinct cutting conditions between
RVE, they established a theoretical model of cutting force for ortho-
tool and CFRP can be formed as follows, as shown in Fig. 2.
gonal machining which considered the influence of fiber orientation,
tool geometry and increasing tool wear. However, those publications
(1) Parallel fiber cutting with θ = 0° (180°). The cutting speed direction
didn’t study the stress state of carbon fiber and resin microelements and
is consistent with the fiber orientation.
the formation mechanism of machined surface defects at the micro
(2) Perpendicular fiber cutting with θ = 90°. The cutting speed direc-
level, and didn’t analyze the fracture mechanism of carbon fibers and its
tion is perpendicular to the fiber orientation.
effects on machined surface morphology at various fiber orientation
(3) Along fiber cutting with 0° < θ < 90°. There is an acute angle
angles θ in the process of UD-CFRP orthogonal cutting.
between the cutting speed direction and the fiber orientation.
In summary, the material removal process of CFRP is controlled by a
(4) Against fiber cutting with 90° < θ < 180°. An obtuse angle exists
series fiber/resin fracture, and the fracture mode is closely related to
between the cutting speed direction and the fiber orientation.
the fiber orientation angle. In this paper, the cutting mechanism and
surface generation were investigated in terms of the machined surface
Under the above four cutting conditions between tool and carbon
morphologies by orthogonal cutting of UD-CFRP laminates under dif-
fiber, the fracture behavior of carbon fiber is completely different,
ferent fiber orientations. Fracture behavior and its effect on machining
which may be resulted from extrusion fracture, bending fracture or
surface morphologies were comprehensively analyzed from the point of
shear fracture. The significant directionality of carbon fiber leads to
view of fracture mechanics. Surface roughness and micro-structure of
huge differences in compressive strength, flexural strength, and shear
surface defects were also discussed in the paper.
strength in different fiber orientations, resulting in various cutting
mechanism accordingly.
2. Fiber orientation angle θ

Due to its directivity and nonuniformity, the surface formation of

CFRP in the cutting process is different from that of metal material.
Many researchers believe that the fiber orientation angle is an im-
portant factor when discussing the cutting removal mechanism of CFRP

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Q. An, et al. Composite Structures 230 (2019) 111441

4. Results and discussion

4.1. Surface roughness

Fig. 6 illustrates the influence of fiber orientation angle on ma-

chined surface roughness Ra. It can be observed that Ra measured from
both parallel and perpendicular cutting speed directions vary sig-
nificantly with fiber orientation angle θ. Ra in against fiber cutting re-
gion (90° < θ < 180°) is almost 2–5 times greater than that in along
fiber cutting region (0° < θ < 90°). For θ = 150°, the worst surface
quality Ra = 13 μm and Ra = 9 μm are obtained in parallel and per-
pendicular cutting speed directions, respectively. Whereas the optimal
surface finish Ra = 2 μm is achieved for θ = 0°/180°. In along fiber
cutting region, Ra increases slightly with the increase of θ. Fiber or-
ientation angle θ = 90° is the inflection point of change, after which the
against fiber cutting region is reached and Ra increases rapidly followed
by a decrease with the increase of θ. In order to obtain a better surface
quality in cutting of CFRP, cutting at θ = 0°/180° is recommended.

4.2. Surface morphologies with fiber orientation angle θ = 0°/180°

Fig. 2. Four cutting conditions between the tool and fiber orientation.
As shown in Fig. 7, when the fiber orientation angle is 0° (180°), the
direction of the carbon fibers in the cut CFRP laminate is parallel to the
3. Experimental procedures
cutting speed. Therefore, the external load Fc on the workpiece material
to be cut is also parallel to the carbon fiber. Under the action of the
3.1. Workpiece material and cutting tool
parallel external load, the stress state inside the material of the uncut
layer is the compressive stress σ0 along the fiber orientation and the in-
T700/LT-03A UD-CFRP laminates with 60% carbon fiber volume
plane shear stress (τp). Since the in-plane shear strength (92 MPa in the
fraction were used in the experiment. The laminates were isotropically
fiber orientation) of CFRP is much lower than 0° compressive strength
layered in 0° direction with 40 layers and 5 mm thickness. The me-
(1430 MPa), the carbon fiber-resin interfacial layer separation guided
chanical properties of T700/LT-03A are shown in Table 1.
by τp is most likely to occur and expand on the carbon fiber-resin
The size of UD-CFRP laminates was 25 mm × 30 mm, as shown in
bonding interface at the bottom of the uncut layer material where shear
Fig. 3. In the orthogonal cutting tests, the UD-CFRP laminate was
stress is concentrated. This is also the earliest chip separation mode. As
placed in different directions to achieve different fiber orientation an-
the tool advances in the direction of the cutting speed, the separated
gles, i.e., 0°, 15°, 30°, 45°, 60°, 75°, 90°, 105°, 120°, 135°, 150° and 165°.
chips accumulate on the rake face and are subject to intense squeezing
Chemical vapor deposition (CVD) diamond-coated WC/Co cutting tool
and bending. A brittle fracture occurs beyond the 0° compressive
was used with a rake angle of 25°, clearance angle of 15°, and a rounded
strength limit and the bending strength limit of CFRP. The carbon fiber
edge radius of 15 μm, as shown in Fig. 4.
is broken by extrusion or bending, forming powdery chips.
When cutting with the fiber orientations of θ = 0°/180°, the mate-
rial removal mechanism of CFRP is the interface layer separation led by
3.2. Experimental conditions
in-plane shear stress τp and the extrusion fracture separation guided by
0° directional compressive stress σ0, as shown in Fig. 7. The machined
Schematic illustration of orthogonal cutting tests of UD-CFRP la-
surface is mainly formed by the interface layer separation, that is, the
minates is shown in Fig. 5. The experiment was performed on the
carbon fiber-resin interface forms the machined surface by the weaker
KENT-KGS-1020AH surface grinder. The grinding wheel was replaced
breaking strength while not involving breaking behaviors of high
with a specially designed flying cutter disc where the cutting tool was
strength reinforced phase carbon fiber, such as extruding, shearing and
mounted. The worktable of the surface grinder was fixed when the
stretching. The cutting power consumption is small, and it is more
spindle of the grinder rotates, the cutting tool can be driven to perform
likely to form a smooth machined surface.
an orthogonal cutting motion. Table 2 shows the cutting parameters in
Fig. 8 shows the machined surface topographies of CFRP when
orthogonal cutting of UD-CFRP laminate. A scanning electron micro-
cutting with the fiber orientations of θ = 0°. There are fewer fiber
scope JSM7600F was used to characterize the fracture mechanism and
fractures on the machined surface under 0° fiber orientation angle,
surface morphology of the machined UD-CFRP laminate. Surface
which is mainly laid up by long fibers in the longitudinal direction. The
roughness (Ra) was measured by Mitutoyo SJ-210 Portable Surface
surface is relatively flat and smooth. A small number of fiber fractures
Roughness Tester based on the ISO 4288-1997 standards, the GAUSS
are 45° diagonal fractures formed when the fibers which are not com-
filter was used with cut-off length λc = 0.8 mm and evaluation length
pletely separated on the interfacial layer are further extruded by tools.
ln =5 l = 4.0 mm.
In other words, interfacial separation and fiber 0° extrusion fracture are
the main cutting mechanisms in a parallel cutting condition. In addition

Table 1
Mechanical properties of unidirectional CFRP laminates.
Material Tensile strength Young’s modulus in tension Compressive strength (MPa) In-plane shear strength 90° tensile strength Bending strength
(MPa) (GPa) (MPa) (MPa) (MPa)

T700/LT-03A 2450 125 1430 92 70 1580

Note: Unspecified mechanical property parameters all represent the properties in 0° direction.

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Q. An, et al. Composite Structures 230 (2019) 111441

Fig. 3. T700/LT-03A UD-CFRP laminate.

Fig. 4. (a) Photographic image of cutting tool (b) Schematic front view of
cutting tool (c) Schematic isometric view of cutting tool. Fig. 5. (a) Schematic diagram of experimental setup (b) Photographic image of
experimental setup.
to the smooth machined surface of long fibers, there are also some
microscopic surface defects under 0° fiber orientation angle, including Table 2
fiber voids, fiber intermittent damage, and resin ploughing. The fiber Machining parameters in orthogonal cutting of UD-CFRP laminate.
voids are caused by the separation of the chips through the interfacial Fiber orientation θ (°) 0°, 15°, 30°, 45°, 60°, 75°, 90°, 105°, 120°, 135°, 150°
layer stripping of the fibers during the cutting and removal process. The and 165°
intermittent fiber damage includes discontinuous short fiber, fiber Cutting speed vc (m/min) 200
breakage damage with 45° oblique fracture and the damage of the fiber Cutting depth ac (μm) 20

surface caused by the friction mechanism of the flank face and the
ploughing mechanism of the cutter. Because of the damages, the da-
0° fiber cutting, and the machined surface is subject to the friction
maged fiber would lose the original strengthening effect on the overall
mechanism and the ploughing mechanism of the flank face. The resin
structure of UD-CFRP material, thus influencing the material strength.
matrix material will have obvious microscopic ploughing phenomenon.
Resin ploughing is caused by the poor rigidity of CFRP laminates in

4
Q. An, et al.
Fig. 6. Effects of fiber orientation angle on surface roughness Ra.
4.3. Surface morphologies with fiber orientation angle θ = 90°
As shown in Fig. 9, when the fiber orientation angle is 90°, the
carbon fibers are perpendicular to the cutting speed, and the external
load Fc on the workpiece material to be cut is also perpendicular to the
carbon fiber. Under the action of the vertical external load, the stress
state in the uncut layer is the compressive stress (σ90) and the shear
stress (τ90). The stress distribution direction is vertical fiber orientation.
Although vertical fiber orientation (90°) is not the main reinforcement
direction of the CFRP laminate, the cutting separation of CFRP can
hardly occur in such stress condition. This is mainly caused by two
reasons: (i) The compressive strength limit and the shear strength limit
of the carbon fiber and the resin material in the 90° compression di-
rection are high; (ii) The chips are not be removed easily, and the
material of the uncut layer is broken to powdery chips by the cutting
edge of the tool. In the vertical cutting condition, CFRP can neither be
separated from the cutting area because of early chip separation on
weak fiber interface like that in the cutting directions of θ = 0° (180°)
and 0° < θ < 90°, nor leave the cutting area with the bending rotation
of fiber like that in the cutting directions of 90° < θ < 180°. In the
vertical cutting condition, the separation direction of the chip is its
main reinforcement 0° stretching direction, showing the chips are ex-
tremely difficult to be separated. When the tool rake face encounters
resin or carbon fiber and reaches its strength limit, the uncut layer
undergoes brittle fracture and shearing. Chips accumulate on the rake
surface, and extrusion fractures occur, eventually forming powdery
chips. As shown in Fig. 9, in the vertical cutting condition, the removal
mechanism of CFRP is the extrusion fracture separation guided by 90°
direction compressive stress σ90 and shear fracture separation guided by
90° shear stress τ90.
Fig. 10 shows the machined surface topographies of CFRP formed in
the vertical cutting condition. The machined surface with 90° fiber
orientation is mainly composed of regular fiber cross fractures, and the
Fig. 7. Material removal mechanism of CFRP in parallel cutting condition.
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Composite Structures 230 (2019) 111441
surface is flat. The fiber cross fractures regularly arranged on the sur-
face are formed by the shearing action of the cutter, and show a regular
flat fracture, that is, 90° shear fracture of carbon fiber is the main
cutting mechanism in the vertical cutting condition, and regular cross
fractures are formed.
In addition, in the vertical cutting direction, the material of the
uncut layer is perpendicular to 90° compressive stress of the fiber or-
ientation, is transmitted to the workpiece through the continuous fiber
in the opposite direction. The 90° tensile stress perpendicular to the
fiber orientation is formed on the machined surface. When this stress is
beyond the 90° tensile strength limit of CFRP, there may be microcracks
at the carbon fiber-resin interface on the machined surface, as shown in
Fig. 10. The main microscopic surface defects under 90° fiber orienta-
tion angle are 90° tensile microcracks and their extension.
4.4. Surface morphologies with fiber orientation angle 0° < θ < 90°
As shown in Fig. 11, when the fiber orientation angle is between 0°
and 90°, there is an acute angle between the direction of the carbon
fibers (pointing to the uncut material layer) and the cutting speed di-
rection. Therefore, an acute angle also exists between the external load
Fc on the workpiece material and the carbon fiber. Fc is decomposed in
the direction along the fiber (0° direction) and the direction perpendi-
cular to the fiber (90° direction) to obtain two perpendicular compo-
nent forces F0 and F90. F0 is the external load in the parallel cutting
direction, and F90 is the external load in the vertical cutting direction.
Therefore, the separation method of the chips also results from the
combination of the above two methods. First, the material of the uncut
layer is subject to compressive stress and shear stress in 90° direction at
the cutting edge of the tool, and brittle fracture and shear of the matrix
resin and carbon fiber occur. The interface is layered and separated by
the extrusion in 0° direction and the in-plane shear stress. Conse-
quently, the chips slide out of the rake face in the fiber orientation, and
powdery chips are formed. As can be seen from Fig. 11, when cutting in
fiber orientations with 0° < θ < 90°, the chip removal mechanism of
CFRP shows shear and fracture separation guided by 90° shear stress τ90
and 90° compressive stress, as well as interface separation guided by in-
plane shear stress τ90.
Figs. 12 and 13 show the machined surface topographies when
cutting with the fiber orientation angle θ changing from 15° to 75°.
With the increase of θ, the machined surface gradually involves from
long fiber surface in a similar θ = 0° direction to fiber cross fracture
surface in θ = 90° direction. The microscopic detect on the surface also
shows a gradual evolutionary trend:
(i) When cutting with the fiber orientation angle θ < 45°, there is an
obvious resin ploughing phenomenon. Because of the poor rigidity
of the workpiece and the severe machining recovery under these
fiber orientation angles, the flank face of the tool is more likely to
have a friction mechanism and a ploughing mechanism with the
workpiece material. In the fiber orientation of θ = 15°, the main
surface microscopic defects of the fiber gap and the fiber inter-
mittent damage occur in the parallel cutting condition. That is,
Q. An, et al.
Fig. 8. Surface morphologies of UD-CFRP laminates when cutting with 0° fiber orientation.
under the condition with small fiber orientation angles, the fiber
fractures on the surface of UD-CFRP are mainly 90° oblique frac-
tures formed by extrusion fracture. However, the fiber fractures do
not mainly constitute the machined surface. The ploughing-like
resin mainly forms the cutting surface under the influence of fric-
tion mechanism and ploughing mechanism, and the machined
surface is relatively flat and smooth under the condition with a
small fiber orientation angle.
(ii) When cutting with the fiber orientation angle θ ≥ 45°, the ma-
chined surface gradually evolves to the surface characterized by
fiber fractures, which gradually evolve into flat fractures formed by
shear fracture. Only a small amount of fiber fractures is formed by
extrusion fracture. With the increase of θ, the machined surface of
UD-CFRP tends to show a surface consisting of flat shear fracture
features. As shown in Fig. 13, the micro-cracks occur on the ma-
chined surface of θ = 60°. There are two fiber cutting mechanisms
on the machined surface of θ = 75° as oblique fractures formed by
90° extrusion fracture and flat cross fracture formed by 90° shear
fracture. That is, when cutting with the fiber orientation angle
θ ≥ 45°, fiber fracture is dominant on the machined surface of UD-
CFRP. With the increase of fiber orientation angle, flat cross frac-
tures formed by fiber 90° shear fracture are dominant and oblique
fractures formed by fiber 90° extrusion fractures are gradually re-
duced. The machined surface with the fiber orientation angle
θ ≥ 45° shows slightly rougher than that with the fiber orientation
angle θ < 45°.
Fig. 9. Material removal mechanism of CFRP in vertical cutting condition.
6
Composite Structures 230 (2019) 111441
4.5. Surface morphologies with fiber orientation angle 90° < θ < 180°
As illustrated in Fig. 14, an obtuse angle between the carbon fibers
(pointing to the uncut material layer) and the cutting speed direction
when cutting with fiber orientations of 90° < θ < 180°. Considering
the small rake angle of the cutting tool, the uncut layer material is
strongly squeezed with the tool at the rake face rather than the cutting
edge. That is, the external load Fc is concentrated on the rake face of the
tool. Fc is decomposed in the directions along the fiber (0° orientation)
and vertical to the fiber (90° orientation). The load F0 in the 0° direction
generates in-plane shear stress, and interface layer separation is caused
at the carbon fiber-resin interface with poor strength. The uncut layer
mainly composed of the carbon fiber bundle which loses the resin bond
is formed. Since the load F90 in 90° direction acts at the upper part of
the uncut material layer, a bending moment M90 is formed. Under the
action of M90, the uncut material is bent, and the bending degree gra-
dually increases as the tool advances. When the bending strength limit
of the carbon fiber is reached, the material is bent, broken and sepa-
rated. Powdery chips are generated. As shown in Fig. 14, when cutting
with fiber orientations of 90° < θ < 180°, the material removal me-
chanism of CFRP is bending and extraction separation guided by in-
plane bending stress (σM) and 90° compressive stress (σ90) and the in-
terface layer separation guided by in-plane shear stress (τp). Cutting
removal occurs easily, and energy consumption is small. However, since
the crack and tear are easily transmitted to the workpiece when the
carbon fiber is bent and broken, the machined surface is rough, and
composed of torn pits.
Fig. 15 shows the machined surface topographies of UD-CFRP when
cutting with fiber orientations of 120°, 150° and 165°. Compared with
Q. An, et al. Composite Structures 230 (2019) 111441

Fig. 10. Surface morphologies of UD-CFRP laminates when cutting with 90° orientation.

Fig. 11. Material removal mechanism of CFRP when cutting in fiber orientations with 0° < θ < 90°.

the above three cutting conditions, the machined surface under the
obtuse fiber orientations is rough, and the machined surface is mainly
characterized by voids and pits left by the bent fiber. When cutting with
fiber orientations of 90° < θ < 180°, the carbon fiber in the uncut
layer material is bent and broken after losing the support of the resin
bonding surface. The position where the fracture occurs has a tendency
to propagate into the workpiece material, leading to cracks and torn
pits in CFRP. The void (fiber extraction) is formed because of the tensile
stress on carbon fiber when the carbon fiber bundle continuously bends
in the advancement direction. Consequently, the carbon fiber may be
pulled out of the workpiece material under the tensile stress. In addi-
tion, when cutting with fiber orientations of 90° < θ < 180°, since the
machining rebound phenomenon is not obvious, there is no serious
resin friction and ploughing mechanism that occurs when cutting with
fiber orientations of 0° < θ < 90°.
As shown in Fig. 5, with the change of fiber orientation angle θ, the
machined surfaces with different topographies occur when cutting with
fiber orientations of 90° < θ < 180°. Fig. 15(a) shows that in a rela-
tively small fiber orientation angle θ = 120°, the machined surface is
characterized by a large number of voids after the fibers are pulled out.
When cutting with a fiber orientation angle θ = 150°, the machined
surface presents severe tearing pits, and the roughness is also the worst,
as shown in Fig. 5(b). In the cutting process of UD-CFRP in this or-
ientation, the pits gradually expand into the workpiece. When cutting
with fiber orientation angle θ = 165°, there are fewer tearing pits on
the machined surface, and the relatively smooth surface is laid by fiber

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Q. An, et al.
Fig. 12. Surface morphologies of UD-CFRP laminates when cutting with orientations of 15°, 30° and 45°.
longitudinally, as shown in Fig. 5(b). Correspondingly, the surface
roughness is improved significantly.
5. Conclusion
This paper investigated the stress state of carbon fiber and resin
microelements and the formation mechanism of machined surface de-
fects at the micro level, and analyzed the fracture mechanism of carbon
fibers and its effects on machined surface morphology at various fiber
orientation angles θ in the process of UD-CFRP cutting. Conclusions are
8
Composite Structures 230 (2019) 111441
as follows.
(1) Cutting UD-CFRP at θ = 0°/180° can fully utilize the shear de-
bonding effect of fiber/resin interface to obtain the optimal surface
quality, by which Ra is reduced by 84.6% relative to the maximum
Ra obtained at other θ.
(2) For θ = 0°/180°, the cutting mechanism is fiber/resin interface
separation dominated by in-plane shear stress. Chips form when the
fibers fractute perpendicular to cutting direction. The machined
surface is mainly laid by long fibers longitudinally, which is
Q. An, et al. Composite Structures 230 (2019) 111441

Fig. 13. Surface morphologies of UD-CFRP laminates when cutting with orientations of 60° and 75°.

Fig. 14. Material removal mechanism of CFRP when cutting in fiber orientations with 90° < θ < 180°.

relatively flat and smooth, and the minimum roughness Ra = 2 μm
is obtained.
(3) In along fiber cutting region 0° < θ < 90°, since the fibers are well
supported, the cutting mechanism is tensile and shearing fracture
parallel and perpendicular to the fiber direction, respectively.
Surface damage includes fiber breakage and resin ploughing.
(4) For θ = 90°, the cutting mechanism is shear fracture of fiber per-
pendicular to fiber direction and subsequent debonding of the
carbon fiber/resin interface which propagates towards free surface.
The machined surface is mainly characterized by regular fiber cross
fractures and residual crack perpendicular to machined surface.
(5) In against fiber cutting region 90° < θ < 180°, the material re-
moval mechanism is shearing or debonding at fiber/resin interface
and bending and subsequent breaking of carbon fibers. The gener-
ated chips are a combination of a large resin matrix and fiber
bundles, resulting in large pits and voids on the machined surface
and deteriorating surface quality (Ra = 13 μm for θ = 150°).
Acknowledgments
This research is supported by National Natural Science Foundation
of China (No. 51605281), SAST-SJTU Joint Research Center for
Aerospace Advanced Technology (USCAST2016-14) and State Key
Laboratory of Mechanical System and Vibration (No. MSVZD201801).

9
Q. An, et al.
Fig. 15. Surface morphologies of UD-CFRP laminates when cutting with fiber orientations of 120°, 150° and 165°.
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