experimental study of milling forces in high-speed milling of bidirectional carbon-carbon composites and development of a quadratic model

Today, bidirectional carbon-carbon (c/c) composites have found wide application in various industries. despite the many challenges in machining these materials, little research has been done. this research makes a groundbreaking contribution by experimentally examining how the cutting speed, feed rate, and orientation of c/c composite layers affect the high-speed milling forces of bidirectional c/c composites with an al2o3 grinding tool. the goal is to reduce machining time and enhance tool longevity, utilizing the response surface method (rsm). for this reason, the parameters mentioned above were assumed as the input parameters, and their effects were investigated on the machining forces (using a milling dynamometer) and tool wear using the central composite design of rsm. two lead models were developed to predict normal and tangential forces in high-speed milling of bidirectional c/c composite. the developed models were then evaluated using three experiments. the results also showed that the orientation of the composite layers has the greatest effect on the milling forces and tool wear after which the tool cutting speed and feed rate respectively. the lowest milling forces were observed at the orientation of (0° and 90°), a feed rate of 0.5 m/min, and a cutting speed of 4521.6 m/min. the orientation of the layers greatly influences chip geometry and dimensions. chips from (30° and 120°) specimens block the tool's porous space, hindering cooling and reducing tool lifespan.