Study on "pull-shear" material removal principle and novel compound structure tool design during cutting KFRP

The Kevlar fiber-reinforced polymer (KFRP) is widely used in various fields due to its excellent mechanical and physical properties. However, the material is prone to processing defects such as burring and furry during secondary processing. In this paper, based on the cutting removal mechanism of KFRP, a "pull-shear" material removal principle for the residual fibers was proposed and analyzed. Then, a novel compound structure milling tool was designed. Theoretical and experimental analyses of the milling tests were carried out on the plain-woven KFRP composites. The result indicates that when the fibers are subjected to tension, the cutting surface quality is significantly improved. Therefore, when the "pull-shear" removal principle can be implemented effectively, the fibers can be effectively cut off in time. The "pulling-shearing" effect can be effectively implemented by the novel compound structure milling tool. The milling surface quality of the novel compound structure milling tool is better than the conventional tools. The burr defect factor gradually decreases with the increase of the feed speed. The burr defect factors tend to increase with the increase in cutting speed.