This work is focused on the study of orthogonal cutting of long fiber composites. A model based in finite element was developed. The mechanisms of chip formation of Glass and Carbon Fiber Reinforced Polymer (FRP) composites were analyzed. Significant differences were observed when comparing machining induced damage predicted with the model for both materials. While damage extended widely ahead the interface and beneath the tool tip in the case of GFRP, damage was located in a much smaller zone in the case CFRP. The fiber orientation influences both the mechanism of chip formation and the induced subsurface damage.
The first objective of this paper is to analyze the influence of mesh size and shape in finite element modeling of composite cutting. Also the influence of the level of energy needed to reach complete breakage of the element is considered. The statement of this level of energy is crucial to simulate the material behavior. On the other hand geometrical characteristics of the tool have significant influence on machining processes. The second objective of the present work is to advance in the knowledge concerning tool geometry and its effect in composite cutting.A two-dimensional finite element model of orthogonal cutting has been developed and validated for Glass LFRP composite, comparing with experimental results presented in scientific literature. It was demonstrated that both numerical parameters and tool geometry influence the predicted chip morphology and machining induced damage.
Damage Out-of-plane failure LFRP (Long Fiber Reinforced) composites are widely used in structural components for high responsibility applications in different industrial sectors. Composite components are manufactured near final shape, however several machining operations are commonly required to achieve dimensional and assembly specifications. Machining should be carefully carried out in order to avoid workpiece damage. Despite of the interest of numerical modeling to analyze in detail the phenomena involved during composite cut ting, there are only few works in the scientific literature dealing with this topic even in the simple case of orthogonal cutting. Out of plane failure can be accounted only if three dimensional modeling is per formed. However up to date numerical analysis of cutting found in scientific literature was focused in two dimensional approach. In this paper (2D) and three dimensional (3D) numerical modeling of orthog onal cutting of carbon LFRP composite are presented. The aim of the paper is to analyze the complex aspects involved during cutting, including out of plane failure.
Machining processes of composites are common operations in industry involving elevated risk of damage generation in the workpiece. Long fiber reinforced polymer composites used in high-responsibility applications require safety machining operations guaranteeing workpiece integrity. Modeling techniques would help in the improvement of machining processes definition; however, they are still poorly developed for composites. The aim of this paper is advancing in the prediction of damage mechanisms involved during cutting, including out-of-plane failure causing delamination. Only few works have focused on three-dimensional simulation of cutting; however, this approach is required for accurate reproduction of the complex geometries of tool and workpiece during cutting processes. On the other hand, cohesive interactions have proved its ability to simulate out-of-plane failure of composites under dynamic loads, as impact events. However, this interlaminar interaction has not been used up to date to model out-of-plane failure induced during chip removal. In this paper, both a classical damage model and cohesive interactions are implemented in a three-dimensional model based on finite elements, in order to analyze intralaminar and interlaminar damage generation in the simplified case of orthogonal cutting of carbon LFRP composite. More realistic damage predictions using cohesive interactions were observed. The strong influence of the stacking sequence on interlaminar damage has been demonstrated.
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