Elliptic vibration-assisted cutting of fibre-reinforced polymer composites: Understanding the material removal mechanisms

This paper develops an elliptic vibration-assisted (EVA) technique to effectively cut fibre-reinforced polymer (FRP) composites using a simple tool. A novel vibrator was invented to work at the anti-resonant frequency to realize stable and high variational velocities. A three-dimensional microstructure-based finite element model was also established to explore the material removal mechanisms in the EVA cutting. It was found that the application of vibration can significantly decrease the cutting forces and reduce the subsurface damage in a workpiece. The vibration in the cutting direction is more effective in reducing the cutting force, but that normal to the cutting direction has the advantage of chip removal. When the vibration is applied to both the directions in the EVA cutting, an optimal cutting process can be reached, providing much smaller cutting forces, a much improved surface integrity, and an extended tool life. The study concluded that the ratio of the tool-feed-rate to the maximum vibration velocity in the cutting direction, and the ratio of the cutting distance in a single tool vibration cycle to the fibre diameter are the key parameters. To maximise the advantage of the EVA cutting, it is necessary that these two parameters are below their critical values.