Numerical investigation on orthogonal cutting and damage response of CFRP/Ti6Al4V stacks

Chao Zhang, Keyi Liu, Fernando Cepero-Mejias, Jose L Curiel-Sosa, Chunjian Mao

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CFRP/Ti6Al4V stacks are widely employed in aerospace, automotive and marine applications owing to their superior properties. However, machining these stacked structures pose challenges due to the intrinsic difference in the mechanical properties of CFRP and Ti6Al4V. Such difference can induce distinct failure mechanisms and chip formation processes compared to those observed in individual materials. This paper presents an explicit finite element (FE) modeling to predict the cutting forces and analyze the induced damage during the orthogonal cutting process. The proposed FE model is validated using available experimental data for separate CFRP and Ti6Al4V conditions before being applied to simulate the cutting behavior of CFRP/Ti6Al4V stacks. The effects of fiber angles, cutting sequences and cutting parameters on the cutting performance and damage mechanism of CFRP/Ti6Al4V stacks are investigated in detail. This work provides insights into the cutting behavior of CFRP/Ti6Al4V stacks and facilitates the optimization of machining process for such composite system.
Original languageEnglish
Pages (from-to)(In-Press)
Number of pages21
JournalJournal of Thermoplastic Composite Materials
Early online date18 Feb 2024
Publication statusE-pub ahead of print - 18 Feb 2024

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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).


  • CFRP/Ti6Al4V stacks
  • cutting behavior
  • damage mechanism
  • interface
  • FE modeling


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