Impact effect-based dynamics force prediction model of high-speed dry milling UD-CFRP considering size effect

•The impact and size effect are first used in the presented model. The paper demonstrates that the impact effect and size effect are important in revealing the cutting mechanism of CFRP.•Based on the size effect and contact position of cutting edge and workpiece, cutting region is first divided into four parts which is effected by chipping, pressing, impacting and bouncing respectively.•The model of carbon fibers distribution is introduced into the presented model as another factors of cutting region division. The impact and size effect are generally neglected in force prediction model of cutting Carbon Fiber Reinforced Polymer (CFRP). Since carbon fibers are frequently cut in and out, the main cutting mechanisms of CFRP are mixed by impact, shear and other mechanisms, which are difficult to be clarified. Thus, we establish an impact effect-based cutting force prediction model of CFRP considering size effect. In the model, cutting regions are effected by chipping, pressing, impacting and bouncing, respectively. The cutting force is calculated based on the representative volume element (RVE) and minimum potential energy principle (MPEP). After chip breakage, the free-damped vibration force prediction model is established. The dynamics force prediction model is proofed with high prediction accuracy. Besides, the influences of cutting parameters on impact, cutting and vibration are analyzed by nonlinear regression analysis. It demonstrates that the impact and size effect are of great significance in revealing the cutting mechanisms of CFRP.