Carbon-fiber-reinforced polymers (CFRPs) have been widely used in many industrial fields, such as automobile, aerospace and so on, because of their excellent mechanical properties. However, due to their anisotropy and inhomogeneity, machining CFRPs is a great challenge. In this paper, the slot milling of a plain-woven CFRP with PCD tools is carried out, and the effects of cutting parameters and tool rake angle on cutting force and surface roughness are studied. The results show that the 4° rake angle PCD tool has smaller cutting force than the 0° rake angle PCD tool, but the effect of rake angle on surface roughness is not significant. The concept of equivalent cutting area is introduced to study the variation law of cutting force and surface roughness. It is found that the cutting force and surface roughness increase with the increase in equivalent cutting area, and decrease with the decrease in equivalent cutting area. The removal mechanism of surface materials under different equivalent cutting areas is different, which leads to the difference in surface roughness. Finally, the causes of delamination on the top layer after milling are explained.
Keywords: cutting force; delamination; equivalent cutting area; surface roughness; woven CFRP.