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

doi:10.1177/08927057241234877

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

Centre for Future Transport and Cities

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Abstract

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 language	English
Pages (from-to)	3492-3515
Number of pages	24
Journal	Journal of Thermoplastic Composite Materials
Volume	37
Issue number	11
Early online date	18 Feb 2024
DOIs	https://doi.org/10.1177/08927057241234877
Publication status	Published - Nov 2024

Bibliographical note

Copyright © and Moral Rights are retained by the author(s) and/ or other copyright owners. A copy can be downloaded for personal non-commercial research or study, without prior permission or charge. This item cannot be reproduced or quoted extensively from without first obtaining permission in writing from the copyright holder(s). The content must not be changed in any way or sold commercially in any format or medium without the formal permission of the copyright holders.

This document is the author’s post-print version, incorporating any revisions agreed during the peer-review process. Some differences between the published version and this version may remain and you are advised to consult the published version if you wish to cite from it.

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
State Key Laboratory of Mechanics and Control for Aerospace Structures	MCAS-E-0124G03
Nanjing University of Aeronautics and Astronautics	MCAS-E-0124G03

Keywords

CFRP/Ti6Al4V stacks
cutting behavior
damage mechanism
interface
FE modeling

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1177/08927057241234877

Cepero-Mejias2024AAMAccepted author manuscript, 2.01 MB

Cite this

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abstract = "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.",

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

Abstract

Bibliographical note

Funder

Funding

Keywords

UN SDGs

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