Theoretical and experimental study of slotting CFRP material with segmented helix tool

In the present work, we studied the slotting process of carbon fiber-reinforced plastic (CFRP) material with segmented helix tool. Measurements of transverse and longitudinal surface roughness, cutting efforts, and consumed power are carried out for different combinations of cutting speed and feed per tooth in order to evaluate the influence of the cutting conditions on the machined surface quality and energy consumption. Transverse (correspondingly longitudinal) roughness refers to roughness measured perpendicular to the advance direction (correspondingly in the advance direction). Scanning electron microscope (SEM) images have been taken in order to see closely surface topography and damages that occur to the machined surface. From the results, it was found that longitudinal roughness values depend on cutting conditions which is not the case for the transverse roughness and feed per tooth makes the highest statistical and physical influence on surface roughness, cutting force, and the consumed power values. SEM images showed the presence of four different material removal mechanisms that can cause damage to the matrix or/and fibers and may generate an increase in roughness measurements.