| Summary: | We propose a flexible circular saw for high-speed cutting of curved lines in carbon fiber-reinforced plastic (CFRP). A conventional circular saw is appropriate for straight line cutting, but it cannot be applied to curved line cutting because of the interference between the saw body and the machined surface. To eliminate this problem, the flexible circular saw is deflected into a bowl shape by circular forced displacement, and the cross-section of the saw becomes a circular arc. A curved line can be cut by the bowl-like-deflection. The deflection shape is very important to realize the curved-line cutting without interference. We investigated the deflection of the flexible circular saw by a finite element method (FEM) analysis. Suitable slit shapes for the saw body are also proposed, based on the FEM results regarding stress in the saw body, the minimum radius of curvature, and the effects of cutting force and centrifugal force and eigenvalue. We also conducted a curved-line cutting test on a CFRP plate, and we found that the flexible circular saw can cut curved lines with high accuracy and high speed without interference between the saw body and the machined surface.
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