Chip formation in orthogonal trimming of graphite/epoxy composite

The mechanisms of chip formation in edge trimming of graphite/epoxy laminates with polycrystalline diamond tools were studied. Characteristics of chip formation were found to be primarily dependent on fibre orientation, with only secondary effects from tool geometry and operating conditions. Although discontinuous chips were noted with all tool/material combinations, variation in the chip geometry depicted a change in chip formation mechanisms with fibre orientation. Spectral analysis of the cutting force signatures and machined surface profiles were used to distinguish changes in chip geometry with fibre orientation and tool geometry. An increase in the rake angle of the cutting tool insert was found to localize the extent of fracture from the tool nose, resulting in smaller discontinuous chips and giving rise to a higher machined surface quality.