CFRP composite manufacturers seek superior surface qualities for use in high-tech sectors. Due to anisotropy and heterogeneity, CFRP is considered a difficult-to-cut material, and diamond abrasives are a preferable choice for machining. Therefore, a better understanding of the impact of diamond abrasive cutting depth on the reinforcing carbon fiber’s breakage pattern paves the way for improved machined surface characteristics. So, the impact of diamond abrasive cutting depth is analyzed on CFRP surface characteristics through cutting forces, surface roughness, and morphology of the abraded constituents of the composite material. Diamond abrasives entangled in ultra-thin dicing blades are utilized to investigate the impact of cutting depth of diamond abrasives for machining unidirectional T700 CFRP composites. Characteristics of the machined surface have been assessed using analysis of variance for cutting depth of diamond abrasives along with varying cutting speeds and feed rates. Findings reveal a higher impact of diamond abrasive cutting depths for process forces and surface roughness than cutting speed and feed rate. Surface morphology analysis revealed the impact of diamond abrasive cutting depth on carbon fiber breakage patterns and matrix deformation. Moreover, the coupling influence of diamond abrasive cutting depth with speed influences the debonding depth of reinforcing fibers which results in the degradation of surface quality.
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