Journal
COMPOSITE STRUCTURES
Volume 214, Issue -, Pages 439-450Publisher
ELSEVIER SCI LTD
DOI: 10.1016/j.compstruct.2019.02.012
Keywords
Machining; Induced machining damage; Finite element; Modelling; Orthogonal cutting; Composite
Categories
Funding
- Industrial Doctoral Centre (IDC) of Sheffield
- Engineering and Physical Sciences Research Council (EPSRC)
- Natural Science Foundation of Jiangsu Province [BK20180855]
- China Postdoctoral Science Foundation [2018M640459]
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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 degrees to 90 degrees.
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