Effect of machining conditions for enhanced surface integrity and cutting temperature in trimming hybrid fibre-reinforced polymer composites

Syed Mohd Fadly Syed Hassan; Syahrul Azwan Sundi; Mohd Hakim Mohd Ramaly; Izzat Afandi Abdul Hakim; Mazran Ahmad; Raja Izamshah Raja Abdullah; Intan Sharhida Othman; Raymond Loh

doi:10.15282/ijame.23.1.2026.14.1012

Authors

Syed Mohd Fadly Syed Hassan Faculty of Industrial and Manufacturing Engineering and Technology (FTKIP), Universiti Teknikal Malaysia Melaka (UTeM), Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
Syahrul Azwan Sundi Faculty of Industrial and Manufacturing Engineering and Technology (FTKIP), Universiti Teknikal Malaysia Melaka (UTeM), Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
Mohd Hakim Mohd Ramaly Faculty of Industrial and Manufacturing Engineering and Technology (FTKIP), Universiti Teknikal Malaysia Melaka (UTeM), Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
Izzat Afandi Abdul Hakim Faculty of Industrial and Manufacturing Engineering and Technology (FTKIP), Universiti Teknikal Malaysia Melaka (UTeM), Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
Mazran Ahmad Faculty of Industrial and Manufacturing Engineering and Technology (FTKIP), Universiti Teknikal Malaysia Melaka (UTeM), Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
Raja Izamshah Raja Abdullah Faculty of Industrial and Manufacturing Engineering and Technology (FTKIP), Universiti Teknikal Malaysia Melaka (UTeM), Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
Intan Sharhida Othman Faculty of Industrial and Manufacturing Engineering and Technology (FTKIP), Universiti Teknikal Malaysia Melaka (UTeM), Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia
Raymond Loh Evertools Industrial Supply Sdn. Bhd. 7, Jalan Perusahaan Sungai Lokan 3, Taman Industri Sungai Lokan, 13800 Butterworth, Pulau Pinang

DOI:

https://doi.org/10.15282/ijame.23.1.2026.14.1012

Keywords:

HFRP, Spindle speed, Feed per tooth, Surface quality, Cutting temperature, Taguchi Orthogonal Array

Abstract

This study aims to evaluate how cutting parameters influence surface quality and cutting temperature during the trimming of Hybrid Fibre Reinforced Polymer (HFRP) used in aerospace components. Although HFRP is increasingly adopted in aircraft structures, it remains difficult to machine because trimming can trigger delamination, matrix degradation, and non-uniform heat generation across the laminate. To address this, a Taguchi L9 Orthogonal Array was applied to systematically examine the effects of spindle speed and feed per tooth on two key outcomes: surface roughness (R_a) and maximum cutting temperature (T_max). Trimming experiments were performed on a Roland MDX540 CNC router, and surface integrity was assessed using optical microscopy, thermal imaging, and analysis of variance. Two parameter settings emerged as optimal, depending on the targeted response. The lowest surface roughness was achieved at 7518 RPM with 0.10 mm per tooth (R_a = 2.44 µm), whereas the lowest cutting temperature occurred at 5012 RPM with 0.15 mm per tooth (T_max = 110.2 °C). Since surface integrity is the primary quality requirement for aerospace trimming, the condition of 7518 RPM / 0.10 mm per tooth was selected as the most practical optimum. This setting provides a noticeably improved surface finish while keeping the cutting temperature at a moderate level (approximately 115 °C), which remains safely below the threshold for polymer matrix degradation. Analysis of variance results further indicate that feed per tooth is the dominant factor governing surface roughness, while spindle speed has the strongest influence on cutting temperature. Overall, the findings support a dual-objective optimisation approach that balances mechanical surface integrity and thermal control, providing practical parameter guidance for consistent, high-quality trimming of HFRP aerospace parts.

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