Chip formation in machining of unidirectional carbon fibre reinforced polymer laminates: FEM based assessment

F. Cepero-Mejias; J. L. Curiel-Sosa; K. Kerrigan; V. A. Phadnis

doi:10.1016/j.procir.2019.09.005

Chip formation in machining of unidirectional carbon fibre reinforced polymer laminates: FEM based assessment

F. Cepero-Mejias, J. L. Curiel-Sosa, K. Kerrigan, V. A. Phadnis

Research output: Contribution to journal › Conference article › peer-review

9 Citations (Scopus)

Abstract

Finite-element (FE) method offers a low cost virtual alternative to assist in optimisation of critical process parameters in machining of composites. This study is focussed on understanding the mechanics of chip formation in orthogonal cutting of unidirectional (UD) carbon-fibre-reinforced polymer (CFRP) laminates through development of FE models. Machining responses of UD CRFP laminates with fibre orientation of 45°(measured with respect to the cutting direction) are assessed. Modelling of material removal in the form of fragmented chips is considered. Damage initiation is determined using the Hashin stress criterion for the fibre component, while matrix failure predicted using Puck criteria. Subsequent damage evolution events are modelled using a strain-based softening approach to degrade relevant material properties linearly. Primary numerical results compared with experimental data revealed that developed FE models are able to predict global machining responses (i.e. cutting forces) and characterise various discrete damage modes associated with machining response of quasi-brittle CFRP laminates successfully. The models also provide a valuable insight into variation in chip morphology.

Original language	English
Pages (from-to)	302-307
Number of pages	6
Journal	Procedia CIRP
Volume	85
DOIs	https://doi.org/10.1016/j.procir.2019.09.005
Publication status	Published - 30 Dec 2020
Externally published	Yes
Event	2nd CIRP Conference on Composite Material Parts Manufacturing, CIRP-CCMPM 2019 - Sheffield, United Kingdom Duration: 10 Oct 2019 → 11 Oct 2019

Bibliographical note

Funding Information:
This work was funded by the Engineering and Physical Sciences Research Council (EPSRC) institution with the grant EP/L016257/1 and a special mention is deserved to the Industrial Doctoral Centre (IDC) of Sheffield for their effective technical support in the development of this project.

Publisher Copyright:
© 2nd CIRP Conference on Composite Material Parts Manufacturing,CIRP-CCMPM 2019. All rights reserved.

Keywords

Composite
Damage
Finite element
Hashin failure criteria
Machinnig
Orthogonal cutting
Puck failure criterion

ASJC Scopus subject areas

Control and Systems Engineering
Industrial and Manufacturing Engineering

Access to Document

10.1016/j.procir.2019.09.005

Cite this

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title = "Chip formation in machining of unidirectional carbon fibre reinforced polymer laminates: FEM based assessment",

abstract = "Finite-element (FE) method offers a low cost virtual alternative to assist in optimisation of critical process parameters in machining of composites. This study is focussed on understanding the mechanics of chip formation in orthogonal cutting of unidirectional (UD) carbon-fibre-reinforced polymer (CFRP) laminates through development of FE models. Machining responses of UD CRFP laminates with fibre orientation of 45°(measured with respect to the cutting direction) are assessed. Modelling of material removal in the form of fragmented chips is considered. Damage initiation is determined using the Hashin stress criterion for the fibre component, while matrix failure predicted using Puck criteria. Subsequent damage evolution events are modelled using a strain-based softening approach to degrade relevant material properties linearly. Primary numerical results compared with experimental data revealed that developed FE models are able to predict global machining responses (i.e. cutting forces) and characterise various discrete damage modes associated with machining response of quasi-brittle CFRP laminates successfully. The models also provide a valuable insight into variation in chip morphology.",

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note = "Funding Information: This work was funded by the Engineering and Physical Sciences Research Council (EPSRC) institution with the grant EP/L016257/1 and a special mention is deserved to the Industrial Doctoral Centre (IDC) of Sheffield for their effective technical support in the development of this project. Publisher Copyright: {\textcopyright} 2nd CIRP Conference on Composite Material Parts Manufacturing,CIRP-CCMPM 2019. All rights reserved.; 2nd CIRP Conference on Composite Material Parts Manufacturing, CIRP-CCMPM 2019 ; Conference date: 10-10-2019 Through 11-10-2019",

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T2 - 2nd CIRP Conference on Composite Material Parts Manufacturing, CIRP-CCMPM 2019

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AU - Kerrigan, K.

AU - Phadnis, V. A.

N1 - Funding Information: This work was funded by the Engineering and Physical Sciences Research Council (EPSRC) institution with the grant EP/L016257/1 and a special mention is deserved to the Industrial Doctoral Centre (IDC) of Sheffield for their effective technical support in the development of this project. Publisher Copyright: © 2nd CIRP Conference on Composite Material Parts Manufacturing,CIRP-CCMPM 2019. All rights reserved.

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Y1 - 2020/12/30

N2 - Finite-element (FE) method offers a low cost virtual alternative to assist in optimisation of critical process parameters in machining of composites. This study is focussed on understanding the mechanics of chip formation in orthogonal cutting of unidirectional (UD) carbon-fibre-reinforced polymer (CFRP) laminates through development of FE models. Machining responses of UD CRFP laminates with fibre orientation of 45°(measured with respect to the cutting direction) are assessed. Modelling of material removal in the form of fragmented chips is considered. Damage initiation is determined using the Hashin stress criterion for the fibre component, while matrix failure predicted using Puck criteria. Subsequent damage evolution events are modelled using a strain-based softening approach to degrade relevant material properties linearly. Primary numerical results compared with experimental data revealed that developed FE models are able to predict global machining responses (i.e. cutting forces) and characterise various discrete damage modes associated with machining response of quasi-brittle CFRP laminates successfully. The models also provide a valuable insight into variation in chip morphology.

AB - Finite-element (FE) method offers a low cost virtual alternative to assist in optimisation of critical process parameters in machining of composites. This study is focussed on understanding the mechanics of chip formation in orthogonal cutting of unidirectional (UD) carbon-fibre-reinforced polymer (CFRP) laminates through development of FE models. Machining responses of UD CRFP laminates with fibre orientation of 45°(measured with respect to the cutting direction) are assessed. Modelling of material removal in the form of fragmented chips is considered. Damage initiation is determined using the Hashin stress criterion for the fibre component, while matrix failure predicted using Puck criteria. Subsequent damage evolution events are modelled using a strain-based softening approach to degrade relevant material properties linearly. Primary numerical results compared with experimental data revealed that developed FE models are able to predict global machining responses (i.e. cutting forces) and characterise various discrete damage modes associated with machining response of quasi-brittle CFRP laminates successfully. The models also provide a valuable insight into variation in chip morphology.

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KW - Finite element

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KW - Machinnig

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Chip formation in machining of unidirectional carbon fibre reinforced polymer laminates: FEM based assessment

Abstract

Bibliographical note

Keywords

ASJC Scopus subject areas

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