Cutting Forces And Surface Roughness Of Wood Plastic Composites In The Process Peripheral Milling

With the application of WPCs (Wood Plastic Composites) in the world, more and moreWPC products need to be secondary machined in order to meet the application requirement.However, in the WPC product market in China, bad surface qualities after secondary machiningare common phenomenon due to the vacancy of good cutting theories for WPCs secondarymachining. As if now, based on this situation, in order to figure out such problem, a research oncutting forces and surface qualities for WPC products was developed in this paper.Rotation speed (6000r/min,8000r/min and10000r/min), feed speed (1m/min,3m/minand5m/min) and clearance angle of cutting tools (22°,26°and30°) were chose as varyingparameter for machining experiment. Cutting forces and surface roughness were tested bydifferent sensors in this paper in order to get data for analysis.Based on the data acquired in the experiment, theories on cutting forces and surfaceroughness in the process of milling WPCs were analyzed in this paper. Also, regression analysiswas also introduced as a way to make a model for WPCs cutting forces and surface roughnesswhich are useful for industrial application. After that, correlation between cutting forces andsurface roughness were also developed in this paper.(1) Cutting forces for WPCs machining: with the increase of rotation speed, F_Xcuttingforces and F_Ycutting forces will be dramatically decreased. With the increase of feed speed, F_Xcutting forces and F_Ycutting forces will be dramatically increased. Also, with the increase ofclearance angle, cutting forces F_Xand cutting forces F_Ywill increase.Variance analysis was proved that feed speed is significant on cutting forces F_Xand cuttingforces F_Y. Rotation speed and clearance angle could not have significant effect on cutting forcesF_Xand cutting forces F_Y.Based on the data acquired in this experiment, regression analysis could help to buildmodels of F_Xcutting forces and F_Ycutting forces. They are respectively listed as below:F_x=84.097-0.008V+26.333f+2.229αF_y=163.2780.002V+26.750f3.542α(2) Surface roughness for WPCs machining: with the increase of rotation speed,surface roughness of machined surface will be decreased gradually and the surface qualitieswill be improved. With the increase of feed speed, surface roughness of machined surface willbe increased gradually and the surface qualities will be deteriorated. With the increase ofclearance angle, surface roughness of machined surface will be increased as well.Variance analysis was proved that feed speed is significant on surface roughness at thelevel of0.1. Rotation speed and clearance angle could not have significant effect on surface roughness.Based on the data acquired in this experiment, regression analysis could help to buildmodels of surface roughness. They are respectively listed as below:Q=2.860+0.001V+0.212f+0.020α(3) Correlation between cutting forces and surface roughness: coefficient betweencutting forces F_Xand surface roughness (Ra) is0.929. Coefficient between cutting forces FYand surface roughness (Ra) is0.861. The coefficients between cutting forces and surfaceroughness prove that they are in significant positive correlation.