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Machining of CFRP composites is usually described as a challenging process from tool life and surface quality perspectives. To achieve a flawless machined surface at reasonable cutting tool life/cost, an optimum combination of cutting tool material and geometry is the key. The cutting tool angles are of importance as these dictate the cutting mechanism as well as the cutting edge robustness and the introduction of vibration to the machining process opens up new horizons of improvement and stirs further research questions. This article investigates the effect of tools with different geometry possessing different rake angles when used in ultrasonic-assisted edge trimming operation dealing with multidirectional CFRP laminates. A full-factorial experimental design was adopted to analyze the effect of process parameters typically cutting speed, feed rate, rake angle, amplitude, and their interactions. Machining performance indicators were captured which were the cutting forces, tool wear, chip temperature, and surface roughness. The results showed that UAM mode contributed to an increase in the cutting forces, tool wear, and chip temperature compared to the conventional mode. On the other hand, UAM mode improved the quality of the machined surface. Additionally, the ultrasonic mode enhanced the material removal mechanism using a tool with a negative rake angle. [ABSTRACT FROM AUTHOR]

Aluminum alloys 6061-T6 are widely utilized in the automotive, aerospace, and marine industries due to high corrosion resistance, high strength, and good workability and machinability. The machining performance of these alloys depends on several factors including tool's material, coating, and geometry. Cutting tool edge radius is one of the most effective factors in cutting forces, energy requirement, and chip formation during metal cutting. The present article aims to study the interactions between the cutting edge radius and cutting speed, feed rate, and rake angle and examine the impacts of the aforementioned tool geometry and cutting conditions on machining forces, cutting temperature, and chip thickness in cutting an aluminum alloy 6061-T6. Special attention is devoted to examining the influence of the cutting edge radius on machining variables and comparing the results of conventional machining (CM) and high speed machining (HSM). A finite element model was developed to simulate the above interactions and was experimentally validated for different machining parameters. The results demonstrate that although increasing the cutting edge radius clearly raises the machining forces, it has a slight influence on the chip thickness. It is also found that the maximum cutting temperatures remain nearly constant with changes in the tool edge radius, while the average temperatures of the tool tip increase especially in HSM. Furthermore, it was found that the location at which the maximum cutting temperature occurs depends more on cutting conditions and tool geometry than workpiece and tool materials. [ABSTRACT FROM AUTHOR]