Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials

Fayzimatov Shukhrat; Rustamov Bannobjon

doi:doi:10.11648/j.ajma.20261302.12

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Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials

Fayzimatov Shukhrat

, Rustamov Bannobjon^*

Published in American Journal of Mechanics and Applications (Volume 13, Issue 2)

Received: 1 June 2026 Accepted: 10 June 2026 Published: 26 June 2026

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Abstract

Composite materials are widely used in aerospace, automotive, and mechanical engineering industries because of their excellent strength-to-weight ratio, high stiffness, corrosion resistance, and durability under demanding operating conditions. These advantages make them attractive for the production of lightweight and high-performance components. However, the machining of composite materials remains a challenging task due to their heterogeneous structure, anisotropic behavior, and abrasive characteristics. During milling operations, these properties can lead to unstable cutting conditions, increased cutting forces, rapid tool wear, and deterioration of surface quality. The present study investigates the influence of cutting parameters and tool wear on the machining quality of composite materials during CNC milling processes. Particular attention is paid to the effects of cutting speed, feed rate, and depth of cut on the cutting performance and the quality of the machined surface. Experimental investigations were conducted under various machining conditions to evaluate the relationships between process parameters, tool wear progression, and machining outcomes. The results of the study indicate that machining parameters significantly affect cutting force behavior, surface roughness, and tool life. Among the investigated factors, feed rate was found to have the most pronounced influence on cutting force fluctuations, surface finish quality, and the rate of tool wear. An increase in feed rate resulted in higher cutting loads and accelerated wear of the cutting tool, which negatively affected the quality of the machined surface. The findings of this research contribute to a better understanding of composite material machining and provide useful recommendations for selecting optimal CNC milling conditions to improve productivity, reduce tool wear, and achieve higher surface quality.

Published in	American Journal of Mechanics and Applications (Volume 13, Issue 2)
DOI	10.11648/j.ajma.20261302.12
Page(s)	28-34
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2026. Published by Science Publishing Group

Keywords

Composite Materials, Milling Parameters, Surface Roughness, Tool Wear, Composite Milling, Finite Element Modeling

1. Introduction

Tool wear and surface roughness are critical factors directly governing the overall machining quality of composite materials. During the milling process, the highly abrasive nature of reinforcing glass fibers significantly accelerates the degradation of the cutting edge. This progressive tool wear elevates the frictional forces within the cutting zone, subsequently leading to the severe deterioration of the machined surface topography. Experimental investigations have demonstrated that advancements in cutting speed, feed rate, and machining time drastically intensify flank wear, thereby yielding higher surface roughness values

[1-4]

. Consequently, the systematic optimization of cutting parameters is paramount to mitigating tool wear, suppressing edge degradation, and maintaining an acceptable surface finish during the milling of composite structures

[12-15]

2. Experimental Procedures

The contact interaction model between the workpiece and the cutting tool was considered based on a model that takes into account plastic deformation and cutting tool wear

[5-7]

. A hard-alloy cutting tool presented in Table 2 was used. The material was considered as a two-component composite consisting of epoxy resin and glass fiber, as shown in Table 1.

Table 1. Physical and mechanical properties of material.

Density. kg/m³	2 000	2 000
Orthotropic Elasticity
Young's Modulus X direction. Pa	45 000	4.5e+10
Shear Modulus XZ. Pa	5 000	5e+09
Poisson's Ratio XZ	0.3	0.30000
Young's Modulus Y direction. Pa	45 000	4.5e+10
Shear Modulus YZ. Pa	5 000	5e+09
Poisson's Ratio YZ	0.3	0.30000
Young's Modulus Z direction. Pa	10 000	1e+10
Shear Modulus XY. Pa	5 000	5e+09
Poisson's Ratio XY	0.3	0.30000
Orthotropic Stress Limits
Tensile X direction. Pa	1100	1.1e+09
Compressive X direction. Pa	-675	-6.75e+08
Shear XY. Pa	80	8e+07
Tensile Y direction. Pa	1100	1.1e+09
Compressive Y direction. Pa	-675	-6.75e+08
Shear YZ. Pa	80	9e+07
Tensile Z direction. Pa	35	3.6e+07
Compressive Z direction. Pa	-120	-1.3e+08
Shear XZ. Pa	80	9e+07

Table 2. Physical and mechanical properties of VK8 cutting tool.

Stiffness.
Young's Modulus.
Coefficient of linear expansion.
Density.

Surface roughness was measured using a GOYOJO GSR750 Surface Roughness profilometer and tool wear was evaluated using an MMI-2 microscope.

Research data on the variation of cutting tool wear and surface roughness depending on cutting parameters are presented in Tables 3-6.

Table 3. Cutting speed V = 63 m/min, cutting depth t = 5 mm and feed rate S = 0.02 mm/tooth

[8]

Time τ	Wear h. mm	Surface roughness Ra
3	0.05	2.09
6	0.07	2.29
8	0.08	2.88
13	0.09	2.88
16	0.09	3.06
21	0.10	4.35
28	0.11	4.83
32	0.12	5.58
38	0.13	5.68
42	0.13	5.5
45	0.14	5.16
47	0.17	5.49
51	0.19	5.49
54	0.20	5.76
56	0.21	5.95
60	0.21	5.95
63	0.22	5.96
67	0.23	5.94
69	0.23	6.05
72	0.25	5.94
74	0.27	6.27
78	0.28	6.49
81	0.31	7.04

Table 4. Cutting speed V = 63 m/min, cutting depth t = 5 mm and feed rate S = 0.01 mm/tooth

[9]

Time τ	Wear h. mm	Surface roughness Ra
0.55	0.05	2.23
1.1	0.06	2.37
1.63	0.06	2.45
2.75	0.08	2.22
3.85	0.11	2.35
5.51	0.31	2.67

Table 5. Cutting speed V = 628 m/min, cutting depth t = 5 mm and feed rate S = 0.1 mm/tooth

[10, 11]

Time τ	Wear h. mm	Surface roughness Ra
0.18	0.11	5.52
0.38	0.14	5.73
0.56	0.22	7.11
0.93	0.28	7.73
1.34	0.32	7.52

Table 6. Cutting speed V = 628 m/min, cutting depth t = 1 mm and feed rate S = 0.02 mm/tooth.

Time τ	Wear h. mm	Surface roughness Ra
0.98	0.02	2.023
1.98	0.04	2.35
2.94	0.07	3.424
4.95	0.11	2.84
6.93	0.12	3.352
8.95	0.15	2.816
10.87	0.21	2.68
13.89	0.26	4.536
16.85	0.3	2.49

The dependence of cutting tool wear on machining time at cutting speed V = 63 m/min, cutting depth t = 5 mm, feed rates S = 0.02 mm/tooth and S = 0.1 mm/tooth are presented in Figures 1(a) and 1(b).

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Figure 1. Dependence of cutting tool wear on machining time.

The dependence of cutting tool wear on machining time at cutting speed V = 628 m/min, cutting depths t = 5 mm and t = 1 mm, feed rates S = 0.1 mm/tooth and S = 0.02 mm/tooth is presented in Figures 2(a) and 2(b).

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Figure 2. Dependence of cutting tool wear on machining time.

Using the standard algorithm in Microsoft Excel, the coefficients of the mathematical relationship were analyzed. The calculation of coefficients A and B for the relationship: h = A+B⋅τ.

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Figure 3. Calculation of coefficients A and B.

H =A+В∙τ

where:

А =0.0325-V∙0.0148+S∙0.0688+t∙0.0074

В =0.003+V∙0.0493+S∙0.0178+t∙0.0178

The experiments confirmed a linear relationship between the cutting force and the amount of cutting tool wear at V = 63 m/min, S = 0.1 mm/tooth and t = 5 mm, the following relationship was obtained:

P = 1576⋅h - 8.142

where P is the cutting force (N) and h is the flank wear of the cutting tool (mm). Similar relationships can also be obtained for other cutting conditions.

Investigation of the dependence of surface roughness Ra on cutting conditions. The obtained experimental data made it possible to determine two types of relationships:

1) The relationship between the arithmetic mean deviation of the machined surface profile Ra, machining time (τ) and cutting conditions;

2) The relationship between the flank wear of the cutting tool (h) and the arithmetic mean deviation of the machined surface profile Ra.

The relationships obtained at cutting speed V = 63 m/min, cutting depth t = 5 mm and feed rate S = 0.02 mm/tooth are presented in Figure 4.

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Figure 4. Dependence of surface roughness on time.

The relationships obtained at cutting speed V = 628 m/min, cutting depth t = 5 mm and feed rate S = 0.1 mm/tooth are presented in Figure 5.

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Figure 5. Dependence of surface roughness on time.

The relationship between the arithmetic mean deviation of the machined surface profile and time has the following form: Ra = A + B∙τ

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Figure 6. Calculation of coefficients A and B.

where:

A =2.6685+V∙2.2235+S∙5.3893+t∙2.5718

B =0.0537+V∙0.0631+S∙1.9548+t∙0.0488

Experimental data describing the relationship between cutting tool wear and the arithmetic mean deviation of the machined surface profile are presented graphically in Figures 7 and 8. A fragment of the calculation of coefficients A and B for this relationship is shown in Figure 9.

The dependence of surface roughness Ra on tool wear at cutting speed V=63 m/min, cutting depth t=5 mm and feed rate S=0.02 mm/tooth

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Figure 7. Dependence of cutting tool wear on surface roughness.

The dependence of surface roughness Ra on tool wear at cutting speed V = 628 m/min, cutting depth t = 5 mm and feed rate S = 0.1 mm/tooth.

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Figure 8. Dependence of cutting tool wear on surface roughness.

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Figure 9. Fragment of calculation of coefficients A and B.

The relationship between the arithmetic mean deviation of the machined surface profile and flank wear of the cutting tool has the following form: Ra = A + B∙h

where:

A =2.3439+V∙2.2309+S∙4.6263+t∙2.513

B =16.427+V∙1.3843+S∙10.001+t∙3.0194

3. Conclusions

The study investigated the influence of milling parameters on tool wear and surface quality during machining of composite materials. The experimental results confirmed that cutting conditions significantly influence flank wear, cutting force and surface roughness during milling of composite materials. Increasing machining intensity accelerated tool wear and deteriorated the machined surface quality. Mathematical relationships describing the dependence between machining time, tool wear and surface roughness were obtained. The developed models can be used for predicting machining quality and selecting rational cutting conditions for efficient milling of materials.

Abbreviations

τ	Machining Time
h	Flank Wear of the Cutting Tool

Author Contributions

Fayzimatov Shukhrat: Conceptualization, Formal Analysis, Methodology, Supervision, Validation, Writing – review & editing

Rustamov Bannobjon: Data curation, Investigation, Software, Visualization, Writing – original draft, Writing – review & editing, Investigation

Conflicts of Interest

The authors declare no conflicts of interest.

References

[1]	Fayzimatov Sh. N., Rustamov B. N. “Assessment of the Influence of the Structural and Geometrical Parameters of Cutting Tools on Equivalent Stresses Generated in the Cutting Zone” // Scientific and Technical Journal of Fergana State Technical University. 2025. Vol. 29. Special Issue No. 20. pp. 29–33.
[2]	Fayzimatov Sh. N., Rustamov B. N. “Modeling and Investigation of Stresses Acting on Cutting Tools during Milling of Fiberglass Composite Materials” // Scientific and Technical Journal of Fergana State Technical University. 2025. Vol. 29. Special Issue No. 19. pp. 9–12.
[3]	Fayzimatov Sh. N., Rustamov B. N. “Machining Characteristics of Parts Made from Composite Materials” // Scientific and Technical Journal of Fergana State Technical University. 2025. Vol. 29. Special Issue No. 11. pp. 50–54.
[4]	Khusanov Y. Y. “Technological Possibilities for Stabilizing the Drilling Processes of Polymer Composite Materials” // Proceedings of the International Scientific and Technical Conference “Modern Materials, Equipment and Technologies in Mechanical Engineering”. Andijan, 2014. pp. 208–210.
[5]	Khusanov Y. Y. “Application of High-Efficiency Technologies in Machining Composite Materials” // Proceedings of the Scientific and Practical Conference of Faculty Members. 2015. pp. 38–39.
[6]	Khusanov Y. Y. “Current State of Polymer Composite Material Machining” // Proceedings of the Republican Scientific and Practical Conference “Non-Traditional Chemical Technologies and Environmental Problems”. Fergana, 2015. pp. 323–324.
[7]	Valikhonov D. A. “Calculation of Forces Acting during Rolling and Compression Processing of Polymer Material Blanks” // Proceedings of the International Scientific and Practical Conference “Problems and Solutions in Textile and Light Industry under Conditions of Integration of Science and Production”, Namangan Institute of Engineering and Technology. 2022. Vol. 5–6. p. 202.
[8]	Karimov R. Kh., Valikhonov D. A., Mirzayev M. “Selection of Cutting Conditions and Tool Parameters for Machining Polymer Material Blanks” // Economy and Society. 2022. No. 4(95). April. Website: http://www.iupr.ru
[9]	Valikhonov D. A. “Mechanism of Chip Fragmentation during Turning of Polymer Materials” // Scientific and Technical Journal of Fergana State Technical University. 2023. Vol. 27. No. 2. pp. 44–48.
[10]	Maqsood, F. Machining of Carbon Fiber Reinforced Polymer Composites: Doctor of Philosophy (PhD) Dissertation. – University of Sheffield, 2013. 248 p.
[11]	Namburi, S. R. Characterization of Cutting Forces in Milling of Unidirectional and Random Fiber Composites: Master of Science Thesis. University of Washington, 2017. 291 p.
[12]	Fayzimatov B. N., Khusanov Y. Y., Egamberdiyeva D. A. “Influence of the Physical and Mechanical Properties of Polymer Composite Materials on Drilling Productivity” // Proceedings of the Republican Scientific and Technical Conference “Mechanical Engineering Production and Education: Problems and Innovative Solutions”. Fergana, 2019. pp. 233–234.
[13]	Rao, G. V. G., Mahajan, P., Bhatnagar, N. Three-Dimensional Macro-Mechanical Finite Element Model for Machining of Unidirectional Fiber-Reinforced Polymer Composites // Materials Science and Engineering. 2008. No. 498. pp. 142–149.
[14]	Armarego, E. J. A. Predictive Modeling of Machining Operations –A Means of Bridging the Gap Between Theory and Practice // CSME Forum. Hamilton, 2000. pp. 18–27.
[15]	US Patent 5685674. Method of Machining Composites. – 1997.

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Shukhrat, F., Bannobjon, R. (2026). Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials. American Journal of Mechanics and Applications, 13(2), 28-34. https://doi.org/10.11648/j.ajma.20261302.12

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ACS Style

Shukhrat, F.; Bannobjon, R. Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials. Am. J. Mech. Appl. 2026, 13(2), 28-34. doi: 10.11648/j.ajma.20261302.12

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AMA Style

Shukhrat F, Bannobjon R. Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials. Am J Mech Appl. 2026;13(2):28-34. doi: 10.11648/j.ajma.20261302.12

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@article{10.11648/j.ajma.20261302.12,
  author = {Fayzimatov Shukhrat and Rustamov Bannobjon},
  title = {Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials},
  journal = {American Journal of Mechanics and Applications},
  volume = {13},
  number = {2},
  pages = {28-34},
  doi = {10.11648/j.ajma.20261302.12},
  url = {https://doi.org/10.11648/j.ajma.20261302.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ajma.20261302.12},
  abstract = {Composite materials are widely used in aerospace, automotive, and mechanical engineering industries because of their excellent strength-to-weight ratio, high stiffness, corrosion resistance, and durability under demanding operating conditions. These advantages make them attractive for the production of lightweight and high-performance components. However, the machining of composite materials remains a challenging task due to their heterogeneous structure, anisotropic behavior, and abrasive characteristics. During milling operations, these properties can lead to unstable cutting conditions, increased cutting forces, rapid tool wear, and deterioration of surface quality. The present study investigates the influence of cutting parameters and tool wear on the machining quality of composite materials during CNC milling processes. Particular attention is paid to the effects of cutting speed, feed rate, and depth of cut on the cutting performance and the quality of the machined surface. Experimental investigations were conducted under various machining conditions to evaluate the relationships between process parameters, tool wear progression, and machining outcomes. The results of the study indicate that machining parameters significantly affect cutting force behavior, surface roughness, and tool life. Among the investigated factors, feed rate was found to have the most pronounced influence on cutting force fluctuations, surface finish quality, and the rate of tool wear. An increase in feed rate resulted in higher cutting loads and accelerated wear of the cutting tool, which negatively affected the quality of the machined surface. The findings of this research contribute to a better understanding of composite material machining and provide useful recommendations for selecting optimal CNC milling conditions to improve productivity, reduce tool wear, and achieve higher surface quality.},
 year = {2026}
}

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TY  - JOUR
T1  - Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials
AU  - Fayzimatov Shukhrat
AU  - Rustamov Bannobjon
Y1  - 2026/06/26
PY  - 2026
N1  - https://doi.org/10.11648/j.ajma.20261302.12
DO  - 10.11648/j.ajma.20261302.12
T2  - American Journal of Mechanics and Applications
JF  - American Journal of Mechanics and Applications
JO  - American Journal of Mechanics and Applications
SP  - 28
EP  - 34
PB  - Science Publishing Group
SN  - 2376-6131
UR  - https://doi.org/10.11648/j.ajma.20261302.12
AB  - Composite materials are widely used in aerospace, automotive, and mechanical engineering industries because of their excellent strength-to-weight ratio, high stiffness, corrosion resistance, and durability under demanding operating conditions. These advantages make them attractive for the production of lightweight and high-performance components. However, the machining of composite materials remains a challenging task due to their heterogeneous structure, anisotropic behavior, and abrasive characteristics. During milling operations, these properties can lead to unstable cutting conditions, increased cutting forces, rapid tool wear, and deterioration of surface quality. The present study investigates the influence of cutting parameters and tool wear on the machining quality of composite materials during CNC milling processes. Particular attention is paid to the effects of cutting speed, feed rate, and depth of cut on the cutting performance and the quality of the machined surface. Experimental investigations were conducted under various machining conditions to evaluate the relationships between process parameters, tool wear progression, and machining outcomes. The results of the study indicate that machining parameters significantly affect cutting force behavior, surface roughness, and tool life. Among the investigated factors, feed rate was found to have the most pronounced influence on cutting force fluctuations, surface finish quality, and the rate of tool wear. An increase in feed rate resulted in higher cutting loads and accelerated wear of the cutting tool, which negatively affected the quality of the machined surface. The findings of this research contribute to a better understanding of composite material machining and provide useful recommendations for selecting optimal CNC milling conditions to improve productivity, reduce tool wear, and achieve higher surface quality.
VL  - 13
IS  - 2
ER  -

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Author Information

Fayzimatov Shukhrat

The Department of Mechanical Engineering, Fergana State Technical University, Fergana, Uzbekistan

Biography: Fayzimatov Shukhrat is a Doctor of Technical Sciences and a professor in the field of mechanical engineering and manufacturing technology. He has made significant contributions to research on machining processes, composite material processing, cutting tool performance and manufacturing systems. He is the author of numerous scientific articles, educational materials and methodological works devoted to machining technology and modern manufacturing methods. Currently, he works at the Department of Mechanical Engineering of Fergana State Technical University, where he actively participates in scientific research and supervises graduate students and young researchers. His scientific interests include CNC machining, composite material processing, cutting tool wear, surface quality improvement, and optimization of machining parameters. Throughout his academic career, Professor Fayzimatov has supervised numerous postgraduate researchers and has played an important role in the development of engineering education and advanced manufacturing research in Uzbekistan.

Research Fields: Machining Technologies, Composite Material Processing, Cutting Tool Design, High-Speed Machining, Cutting Force Analysis, Tool Wear and Surface Integrity, CNC Manufacturing Systems, Adaptive Control in Machining Processes, Modeling of Technological Processes, Intelligent Manufacturing Technologies.

http://orcid.org/0009-0000-0178-9398
Rustamov Bannobjon

The Department of Mechanical Engineering, Fergana State Technical University, Fergana, Uzbekistan

Biography: Rustamov Bannobjon is a PhD candidate and assistant lecturer at the Department of Mechanical Engineering, Fergana State Technical University, Uzbekistan. He completed advanced professional training abroad and actively collaborates with foreign professors and researchers in the field of advanced manufacturing technologies and composite material processing. He is actively involved in scientific research related to modern machining technologies and intelligent manufacturing systems.

Research Fields: Composite Material Machining, Milling of GFRP Composites, Cutting Force Stabilization, Tool Wear Analysis, Surface Roughness Formation, Finite Element Modeling of Machining Processes, High-Speed Milling Technologies, Adaptive Control of Machining Processes, CNC Manufacturing Technologies, Intelligent Manufacturing Systems.

Contact Email

http://orcid.org/0009-0003-3417-3102

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Shukhrat, F., Bannobjon, R. (2026). Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials. American Journal of Mechanics and Applications, 13(2), 28-34. https://doi.org/10.11648/j.ajma.20261302.12

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ACS Style

Shukhrat, F.; Bannobjon, R. Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials. Am. J. Mech. Appl. 2026, 13(2), 28-34. doi: 10.11648/j.ajma.20261302.12

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AMA Style

Shukhrat F, Bannobjon R. Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials. Am J Mech Appl. 2026;13(2):28-34. doi: 10.11648/j.ajma.20261302.12

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@article{10.11648/j.ajma.20261302.12,
  author = {Fayzimatov Shukhrat and Rustamov Bannobjon},
  title = {Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials},
  journal = {American Journal of Mechanics and Applications},
  volume = {13},
  number = {2},
  pages = {28-34},
  doi = {10.11648/j.ajma.20261302.12},
  url = {https://doi.org/10.11648/j.ajma.20261302.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ajma.20261302.12},
  abstract = {Composite materials are widely used in aerospace, automotive, and mechanical engineering industries because of their excellent strength-to-weight ratio, high stiffness, corrosion resistance, and durability under demanding operating conditions. These advantages make them attractive for the production of lightweight and high-performance components. However, the machining of composite materials remains a challenging task due to their heterogeneous structure, anisotropic behavior, and abrasive characteristics. During milling operations, these properties can lead to unstable cutting conditions, increased cutting forces, rapid tool wear, and deterioration of surface quality. The present study investigates the influence of cutting parameters and tool wear on the machining quality of composite materials during CNC milling processes. Particular attention is paid to the effects of cutting speed, feed rate, and depth of cut on the cutting performance and the quality of the machined surface. Experimental investigations were conducted under various machining conditions to evaluate the relationships between process parameters, tool wear progression, and machining outcomes. The results of the study indicate that machining parameters significantly affect cutting force behavior, surface roughness, and tool life. Among the investigated factors, feed rate was found to have the most pronounced influence on cutting force fluctuations, surface finish quality, and the rate of tool wear. An increase in feed rate resulted in higher cutting loads and accelerated wear of the cutting tool, which negatively affected the quality of the machined surface. The findings of this research contribute to a better understanding of composite material machining and provide useful recommendations for selecting optimal CNC milling conditions to improve productivity, reduce tool wear, and achieve higher surface quality.},
 year = {2026}
}

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TY  - JOUR
T1  - Influence of Milling Parameters on Surface Roughness and Tool Wear During Milling of Composite Materials
AU  - Fayzimatov Shukhrat
AU  - Rustamov Bannobjon
Y1  - 2026/06/26
PY  - 2026
N1  - https://doi.org/10.11648/j.ajma.20261302.12
DO  - 10.11648/j.ajma.20261302.12
T2  - American Journal of Mechanics and Applications
JF  - American Journal of Mechanics and Applications
JO  - American Journal of Mechanics and Applications
SP  - 28
EP  - 34
PB  - Science Publishing Group
SN  - 2376-6131
UR  - https://doi.org/10.11648/j.ajma.20261302.12
AB  - Composite materials are widely used in aerospace, automotive, and mechanical engineering industries because of their excellent strength-to-weight ratio, high stiffness, corrosion resistance, and durability under demanding operating conditions. These advantages make them attractive for the production of lightweight and high-performance components. However, the machining of composite materials remains a challenging task due to their heterogeneous structure, anisotropic behavior, and abrasive characteristics. During milling operations, these properties can lead to unstable cutting conditions, increased cutting forces, rapid tool wear, and deterioration of surface quality. The present study investigates the influence of cutting parameters and tool wear on the machining quality of composite materials during CNC milling processes. Particular attention is paid to the effects of cutting speed, feed rate, and depth of cut on the cutting performance and the quality of the machined surface. Experimental investigations were conducted under various machining conditions to evaluate the relationships between process parameters, tool wear progression, and machining outcomes. The results of the study indicate that machining parameters significantly affect cutting force behavior, surface roughness, and tool life. Among the investigated factors, feed rate was found to have the most pronounced influence on cutting force fluctuations, surface finish quality, and the rate of tool wear. An increase in feed rate resulted in higher cutting loads and accelerated wear of the cutting tool, which negatively affected the quality of the machined surface. The findings of this research contribute to a better understanding of composite material machining and provide useful recommendations for selecting optimal CNC milling conditions to improve productivity, reduce tool wear, and achieve higher surface quality.
VL  - 13
IS  - 2
ER  -

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