Edge Trimming of Graphite/Epoxy with Diamond Abrasive Cutters

The most common method currently employed in industry to trim composites is machining either with conventional fluted cutters or with diamond abrasive cutters. Although diamond abrasive machining is a common method for trimming composites, there is no research literature which addresses the use of this type of cutter. As a result, an experimental investigation was undertaken to establish the characteristics of the machined edges produced by diamond abrasive cutters in graphite/epoxy laminates. In addition, preliminary tests were performed to document the cutter forces produced by representative cutters with various grit sizes and feed rates. The machined edges produced were generally found to be free of delamination and characterized by regular grooving produced by the diamond grains. The surface finish was found to be inversely proportional to the grit number and was not affected by feed rate or cutting mode. Cutter forces were generally found to increase with material removal rate and the average side load was generally about 60 percent of the thrust forces.