Three-dimensional finite element simulations of milling carbon/epoxy composites

Mechanical milling is an extensively used finishing process for fiber-reinforced polymer (FRP) composites. To better understand the characteristics in machining FRPs for higher quality and efficiency, various studies have been conducted based on the finite element (FE) method as it can give insight...

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Published inComposite structures Vol. 282; p. 115037
Main Authors He, Yanli, Li, Long, Wan, Min, Xue, Hongqian
Format Journal Article
LanguageEnglish
Published Elsevier Ltd 15.02.2022
Subjects
CFRP
Cutting force
Failure criterion
FE modeling
Milling
Failure criterion
FE modeling
CFRP
Milling
Cutting force
Online AccessGet full text
ISSN0263-8223
1879-1085
DOI10.1016/j.compstruct.2021.115037

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Abstract Mechanical milling is an extensively used finishing process for fiber-reinforced polymer (FRP) composites. To better understand the characteristics in machining FRPs for higher quality and efficiency, various studies have been conducted based on the finite element (FE) method as it can give insight on the mechanisms of material removal during cutting. Yet there is still a lack of three-dimensional FE models suitable for studying the mechanisms involved in the milling of FRPs. This paper developed a 3D meso-scale FE model for simulating CFRP milling by considering the damage behavior of the composites in 3D stress state. A progressive damage model was proposed and implemented using the VUSDFLD subroutine to predict the continuous damage evolution and stiffness degradation of the laminae. The simulated cutting forces and sub-surface damage agreed with the experimental observations. Numerical studies also showed that the failure criterion affected the simulated cutting forces and sub-surface damage. Upon increasing the tool edge radius, the simulated sub-surface damage affected a larger zone beneath the machined surface; however, the simulated cutting force and the sub-surface post-failure-initiation damage area experienced no obvious changes for the studied edge radius range.
AbstractList Mechanical milling is an extensively used finishing process for fiber-reinforced polymer (FRP) composites. To better understand the characteristics in machining FRPs for higher quality and efficiency, various studies have been conducted based on the finite element (FE) method as it can give insight on the mechanisms of material removal during cutting. Yet there is still a lack of three-dimensional FE models suitable for studying the mechanisms involved in the milling of FRPs. This paper developed a 3D meso-scale FE model for simulating CFRP milling by considering the damage behavior of the composites in 3D stress state. A progressive damage model was proposed and implemented using the VUSDFLD subroutine to predict the continuous damage evolution and stiffness degradation of the laminae. The simulated cutting forces and sub-surface damage agreed with the experimental observations. Numerical studies also showed that the failure criterion affected the simulated cutting forces and sub-surface damage. Upon increasing the tool edge radius, the simulated sub-surface damage affected a larger zone beneath the machined surface; however, the simulated cutting force and the sub-surface post-failure-initiation damage area experienced no obvious changes for the studied edge radius range.
ArticleNumber 115037
Author Xue, Hongqian
Li, Long
Wan, Min
He, Yanli
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Milling
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Snippet Mechanical milling is an extensively used finishing process for fiber-reinforced polymer (FRP) composites. To better understand the characteristics in...
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SubjectTerms CFRP
Cutting force
Failure criterion
FE modeling
Milling
Title Three-dimensional finite element simulations of milling carbon/epoxy composites
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