Mechanistic force modeling for milling of unidirectional carbon fiber reinforced polymer laminates

► Slot and side milling of aerospace quality thick unidirectional CFRP laminates is performed. ► Cutting force coefficients are calculated as a function fiber cutting angle. ► A sine function is used to represent cutting force coefficients. ► Proposed mechanistic force model can calculate milling forces based on multidirectional CFRP laminate configuration. ► Milling at 45° fiber direction is found favorable in terms of forces and surface quality.