Cutting force and hole quality analysis in micro-drilling of CFRP

Micro-drilling in carbon fiber reinforced plastic (CFRP) composite material is challenging because this material machining is difficult due to anisotropic, abrasive and non-homogeneous properties and also downscaling of cutting process parameters affect the cutting forces and micro-drilled hole quality extensively. In this work, experimental results based statistical analysis is applied to investigate feed and cutting speed effect on cutting force components and hole quality. Analysis of variance based regression equation is used to predict cutting forces and hole quality and their trend are described by response surface methodology. Results show that roundness error and delamination factor have similar trends to those of radial forces and thrust force, respectively. Non-linear trends of cutting forces and hole quality errors are observed during downscaling of the micro-drill feed value. Optimization results show that cutting forces and hole quality errors are minimum at a feed value which is almost equal to the tool edge radius rather than at the lowest feed value. Therefore, the presented results clearly show the influences of size effects on cutting forces and hole quality parameters in micro-drilling of CFRP composite material.