Effect of cutter geometry on machining induced damage in orthogonal cutting of UD polymer composites: FE study

F. Cepero-Mejías, J. L. Curiel-Sosa, C. Zhang, V. A. Phadnis

Research output: Contribution to journalArticlepeer-review

33 Citations (Scopus)


This article presents a finite-element analysis (FEA) based study to understand the influence of cutting parameters (rake angle, relief angle and cutter edge radius) on the machining-induced damage of unidirectional (UD) composites. Carbon/epoxy (CFRP) and glass/epoxy (GFRP) composites are considered. Onset of damage in composites is modelled using a combination of maximum stress and Puck's fracture criteria, while a novel damage propagation algorithm is proposed to account for the post-damage material softening behaviour. A spring-back phenomenon (partial elastic recovery of workpiece material after tool passed a cutting surface) often observed in composites machining, is considered in the FE model to allow a better prediction of the thrust force and induced damage. A validated FE model predicts that with increasing relief angle, the extent of sub-surface damage is reduced. Rake angle or tool edge radius are not found to have a great influence on the induced damage. A large dependence is observed between the fibre angle and the induced damage, as the severity of damage increase when fibre orientations varies from 30° to 90°.

Original languageEnglish
Pages (from-to)439-450
Number of pages12
JournalComposite Structures
Early online date10 Feb 2019
Publication statusPublished - 15 Apr 2019
Externally publishedYes


The first author wishes to acknowledge the financial support and technical help provided by the Industrial Doctoral Centre (IDC) of Sheffield and the Engineering and Physical Sciences Research Council (EPSRC) for making possible this paper.
The third author wishes to acknowledge the support by the Natural Science Foundation of Jiangsu Province (BK20180855) and China Postdoctoral Science Foundation (2018M640459).


  • Machining
  • Induced machining damage
  • Finite element
  • Modelling
  • Orthogonal cutting
  • Composite

ASJC Scopus subject areas

  • Ceramics and Composites
  • Civil and Structural Engineering


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