Prediction of cutting forces in ball-end milling of 2.5D C/C composites

Machining of carbon/carbon (C/C) composite materials is difficult to carry out due to its high specific stiffness, brittleness, anisotropic, non-homogeneous and low thermal conductivity, which can result in tear, burr, poor surface quality and rapid wear of cutters. Accurate and fast prediction of cutting forces is important for milling C/C composite materials with high quality. This paper presents an alternative cutting force model involving the influences of the directions of fiber. Based on the calculated and experimental results, the cutting forces' coefficients of 2.5D C/C composites are evaluated using multiple linear regression method. Verification experiment has been carried out through a group of orthogonal tests. Results indicate that the proposed model is reliable and can be used to predict the cutting forces in ball-end milling of 2.5D C/C composites. (C) 2015 The Authors. Production and hosting by Elsevier Ltd. on behalf of Chinese Society of Aeronautics and Astronautics.