Analysis of cutting parameters for trimming carbon, glass and hybrid fiber reinforced polymer laminates using vibration monitoring and surface roughness assessment

Abstract

This study assesses the mechanical properties of four composite materials, including two hybrid composites, produced using the autoclave molding method. Modal analysis shows that carbon fiber reinforced polymer exhibits the highest Young's modulus (91 GPa), while the hybrid carbon/glass and glass/carbon fiber reinforced polymers demonstrate intermediate stiffness, with moduli of 87 GPa and 57.5 GPa, respectively. Glass fiber reinforced polymer presents the lowest Young's modulus, at 28 GPa. The study also examines how cutting parameters—specifically cutting speed, feed per tooth, and width of cut—affect vibration levels during trimming. The results indicate that increasing cutting speed and feed rate leads to higher vibration amplitudes. These parameters also influence surface quality, with measured surface roughness values ranging from 0.45 µm to 0.9 µm. In terms of material comparison, the hybrid composites exhibit vibration behavior and surface finish intermediate between those of carbon-fiber- and glass-fiber-reinforced polymers. The main takeaway is that selecting appropriate cutting parameters is essential to balance surface quality and machining efficiency, particularly for hybrid composite materials.