Numerical investigation on milling performance and damage response of UD-CFRP laminates

Chunjian Mao; Keyi Liu; Fernando Cepero-Mejias; Chao Zhang

doi:10.1080/15376494.2024.2386117

Numerical investigation on milling performance and damage response of UD-CFRP laminates

Chunjian Mao
, Keyi Liu
, Fernando Cepero-Mejias
, Chao Zhang

Centre for Future Transport and Cities

Jiangsu University
Nanjing University of Aeronautics and Astronautics

Research output: Contribution to journal › Article › peer-review

10 Citations (Scopus)

41 Downloads (Pure)

Abstract

Carbon fiber-reinforced polymer (CFRP) is prone to machining defects, including burrs and tearing, during milling. These defects are closely associated with interface delamination while milling force plays a crucial role in their occurrence. In this paper, a nonlinear explicit finite element (FE) model is developed to predict the milling force and analyze the delamination damage occurring during the milling of unidirectional CFRP (UD-CFRP). The proposed FE model is validated through numerical comparison with experimental data for milling force. Moreover, a detailed study is conducted to examine the influences of spindle speed, feed rate and depth-of-cut on the side-milling performance and damage response of UD-CFRP. This study provides valuable insights into the effects of machining parameters on milling force and delamination damage in CFRP, thereby supporting the optimization of machining technology for this composite material system.

Original language	English
Pages (from-to)	2842-2855
Number of pages	14
Journal	Mechanics of Advanced Materials and Structures
Volume	32
Issue number	12
Early online date	31 Jul 2024
DOIs	https://doi.org/10.1080/15376494.2024.2386117
Publication status	Published - 2025

Bibliographical note

2024 Taylor & Francis Group,
This is an Accepted Manuscript version of the following article, accepted for publication in Mechanics of Advanced Materials and Structures. Mao, C, Liu, K, Cepero-Mejias, F & Zhang, C 2025, 'Numerical investigation on milling performance and damage response of UD-CFRP laminates', Mechanics of Advanced Materials and Structures, vol. 32, no. 12, pp. 2842-2855. https://doi.org/10.1080/15376494.2024.2386117
.

It is deposited under the terms of the Creative Commons Attribution-NonCommercial License (http://creativecommons.org/licenses/by-nc/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is properly cited.

Funder

This work was supported by the Natural Science Foundation of Jiangsu Province [BK20231319] and State Key Laboratory of Mechanics and Control for Aerospace Structures (Nanjing University of Aeronautics and astronautics) [MCAS-E-0124G03].

Funding

This work was supported by the Natural Science Foundation of Jiangsu Province [BK20231319] and State Key Laboratory of Mechanics and Control for Aerospace Structures (Nanjing University of Aeronautics and astronautics) [MCAS-E-0124G03].

Funders	Funder number
Natural Science Foundation of Jiangsu Province	BK20231319
Nanjing University of Aeronautics and Astronautics	MCAS-E-0124G03

Keywords

UD-CFRP
milling
machining parameters
delamination
finite element modeling

Access to Document

10.1080/15376494.2024.2386117

Cepero-Mejias2024AAMAccepted author manuscript, 2.31 MBLicence: CC BY-NC

Cite this

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title = "Numerical investigation on milling performance and damage response of UD-CFRP laminates",

abstract = "Carbon fiber-reinforced polymer (CFRP) is prone to machining defects, including burrs and tearing, during milling. These defects are closely associated with interface delamination while milling force plays a crucial role in their occurrence. In this paper, a nonlinear explicit finite element (FE) model is developed to predict the milling force and analyze the delamination damage occurring during the milling of unidirectional CFRP (UD-CFRP). The proposed FE model is validated through numerical comparison with experimental data for milling force. Moreover, a detailed study is conducted to examine the influences of spindle speed, feed rate and depth-of-cut on the side-milling performance and damage response of UD-CFRP. This study provides valuable insights into the effects of machining parameters on milling force and delamination damage in CFRP, thereby supporting the optimization of machining technology for this composite material system.",

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N1 - 2024 Taylor & Francis Group, This is an Accepted Manuscript version of the following article, accepted for publication in Mechanics of Advanced Materials and Structures. Mao, C, Liu, K, Cepero-Mejias, F & Zhang, C 2025, 'Numerical investigation on milling performance and damage response of UD-CFRP laminates', Mechanics of Advanced Materials and Structures, vol. 32, no. 12, pp. 2842-2855. https://doi.org/10.1080/15376494.2024.2386117 . It is deposited under the terms of the Creative Commons Attribution-NonCommercial License (http://creativecommons.org/licenses/by-nc/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is properly cited.

PY - 2025

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N2 - Carbon fiber-reinforced polymer (CFRP) is prone to machining defects, including burrs and tearing, during milling. These defects are closely associated with interface delamination while milling force plays a crucial role in their occurrence. In this paper, a nonlinear explicit finite element (FE) model is developed to predict the milling force and analyze the delamination damage occurring during the milling of unidirectional CFRP (UD-CFRP). The proposed FE model is validated through numerical comparison with experimental data for milling force. Moreover, a detailed study is conducted to examine the influences of spindle speed, feed rate and depth-of-cut on the side-milling performance and damage response of UD-CFRP. This study provides valuable insights into the effects of machining parameters on milling force and delamination damage in CFRP, thereby supporting the optimization of machining technology for this composite material system.

AB - Carbon fiber-reinforced polymer (CFRP) is prone to machining defects, including burrs and tearing, during milling. These defects are closely associated with interface delamination while milling force plays a crucial role in their occurrence. In this paper, a nonlinear explicit finite element (FE) model is developed to predict the milling force and analyze the delamination damage occurring during the milling of unidirectional CFRP (UD-CFRP). The proposed FE model is validated through numerical comparison with experimental data for milling force. Moreover, a detailed study is conducted to examine the influences of spindle speed, feed rate and depth-of-cut on the side-milling performance and damage response of UD-CFRP. This study provides valuable insights into the effects of machining parameters on milling force and delamination damage in CFRP, thereby supporting the optimization of machining technology for this composite material system.

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Numerical investigation on milling performance and damage response of UD-CFRP laminates

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