Effect of flax fiber orientation on machining behavior and surface finish of natural fiber reinforced polymer composites

Abstract

Manufacturing processes of natural fiber reinforced polymer (NFRP) composites are becoming the interest of industrials and scientists because these eco-friendly materials are emerging in automotive and aerospace industries. In this context, machining processes of NFRP composites present significant issues related to the complex structure of natural fibers that need thorough tribological studies. This paper aims to explore the effect of natural fiber orientation on the machinability of NFRP composites using Merchant model in order to separate the shearing energy from the friction energy. Orthogonal cutting process is conducted on unidirectional flax fibers reinforced polypropylene composites by changing the fiber orientation from 0° to 90° with respect to the cutting direction. Iosipescu shear tests are also performed to determine the mechanical shear behavior in function of the fiber orientation. Results show the applicability of Merchant model on the machining analysis of NFRP composites by verifying the main model assumptions. The fiber orientation affects significantly the shearing and the friction energies that control the cutting behavior and the chip formation of the NFRP composite. The resulted machined surfaces are hence intimately related to the natural fiber orientation.