Chip formation processes based on orthogonal processing of polymer composite materials

This paper presents the results of the study of processes occurring in the cutting zone during the processing of polymer composite materials. The research included determining the effects of orthogonal cutting conditions, such as the cutting depth t and cutting rate v, on the tangential component Pz of the cutting force, the length lc of chips, as well as the vibration acceleration W, to clarify the results previously submitted to the scientific community and obtain new data. The study included 12 experiments for different cutting conditions with the cutting depth t varying in the range of 0.1—0.4 mm and the cutting rate — in the range of 6.7—30.2 m/min. The experimental results allowed to determine a range of cutting rates that lead to a low level of elastic deformations of reinforcing fibers. Based on the dynamics of increasing cutting forces in various cutting conditions, tool cutting edge wear, type and length of chips, as well as the vibration acceleration dynamics, we have found that reinforcing composite material fibers accumulate on the tool cutting edge, while elastic fracture of these fibers causes defect formation on the processed surface. The analysis allows giving recommendations on the need for research in the field of abrasive machining with rigid grinding wheels due to the highest hardness of the cutting tool surface, increased machining speed and the possibility of self-sharpening during tool wear.