The influence of tool structure on multiphase fiber and particle reinforced polymer matrix composites: Removal mechanism and experimental verification

Due to the presence of both ductile fibers and brittle fibers in multiphase fiber and particle reinforced polymer matrix composites (MFPRP), understanding the removal mechanism of different physical property fibers by the tool structure is crucial for achieving high-quality processing. For this, this study investigated the removal mechanisms of different fiber phases through scratch tests using single diamond tool and orthogonal edges. Specifically, it was found that the specific cutting energy of the orthogonal edges was lower than that of the single diamond tool, and the resulting groove size was closer to the theoretical value; the single diamond tool would cause widespread microcracks and fiber fractures, while the orthogonal edges would lead to fiber debonding and a unique “coating” effect. Additionally, it was discovered that at 0°, the ductile fibers would exhibit fiber rebound when using a single diamond tool. Moreover, experimental verification was conducted using grinding tool and milling tool to validate the findings, indicating that the quality of removal by the shaped cutting edge is higher. These findings contribute to a deeper understanding of the cutting process and provide new ideas for improving the processing technology of composite materials.