Numerical studies of frictional responses when cutting hybrid CFRP/Ti composite

In manufacturing sectors, machining hybrid CFRP/Ti is usually an extremely challenging task due to the disparate natures of each stacked constituent involved and their respectively poor machinability. The current research focus of hybrid CFRP/Ti cutting was primarily made via the experimental studies, which exhibited high cost and time consuming. In this paper, a new contribution was provided to study the key frictional responses dominating the bi-material machining via the numerical approach. To this aim, a multi-physical model was developed by implementing different constitutive laws and damage criteria to construct the anisotropic machinability of the stacked composite. The interrelated effects of the multi-tool-work frictional behavior on hybrid CFRP/Ti cutting were precisely investigated with respect to the specific cutting energy consumption, machined surface morphology, and affected subsurface damage. A special focus was made to clarify the cutting sequence's influences on the hybrid cutting operation. The numerical results highlighted the reasonable CFRP -> Ti cutting sequence for hybrid composite machining and the pivotal role of multi-tool-work interaction in affecting the frictional responses induced by cutting.