Effects of machine stiffness and cutting tool design on the surface quality and flexural strength of edge trimmed carbon fibre reinforced polymers

A 22 full factorial design of experiment is used to investigate the effects of two machining platforms (5-axis elevated gantry versus 6-axis articulated robotic system) and two cutting tool designs (burr versus herringbone) on surface metrics and flexural strength of a 14 ply T300 2x2 carbon fibre reinforced polymer.

A range of areal metrics were considered to characterise the surface with Sal and Stdi best able to represent differences due to the choice of robotic system or overhead gantry. The robotic system produces coupons with flexural strengths up to 26% higher than the overhead gantry. The choice of tool has a less significant effect however machine-tool interactions do play a role in the flexural strength.

Analysis using scanning electron microscopy shows that defects may be obscured by smeared matrix which may contribute to overall flexural strength differences.