2D and 3D Finite Element Models for the Edge Trimming of CFRP

Duboust, Nicolas; Pinna, C.; Ghadbeigi, Hassan; Ayvar-Soberanis, Sabino; Phadnis, Vaibhav A.; Collis, Andrew; Kerrigan, Kevin

doi:10.1016/j.procir.2017.03.217

Cited by 12 publications

(9 citation statements)

References 11 publications

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“…The main cutting force of climb and conventional milling are expressed by Eqs. (8) and (9), respectively. The models were developed based on regression analysis and validated by graphical adequate analysis.…”

Section: Comparison and Discussionmentioning

confidence: 99%

“…In the aerospace industry, as well as in the automotive, wind turbine, military, sports, and aerospace industries, manufacturers strive to laminate CFRP components in a single operation (moulding and hardening); however, they often require further processing before they can be used or assembled [4][5][6]. These may include (i) removing material build-up in the dividing plane of the laminating tool, (ii) removing excess material from the flange of the laminating tools, (iii) smoothing the mating surfaces of the laminated composites, and (iv) making holes for assembly of components [7][8][9]. Typically, these post-manufacturing needs are met by various machining techniques, like conventional drilling, helical milling, tilted helical milling, wobble milling, side milling, or edge trimming [6,[10][11][12][13].…”

Section: Introductionmentioning

confidence: 99%

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Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Geier

2020

Int J Adv Manuf Technol

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Machining of carbon fibre reinforced polymer (CFRP) composites is extremely difficult, mainly due to their inhomogeneous and anisotropic properties. Predicting of cutting force during machining of CFRP is also difficult because the machinability properties of the composite are significantly orientation-dependent (fibre and machining directions). The main objective of the present study is to analyse the influence of fibre orientation on cutting force in milling of unidirectional CFRP. Up and down milling experiences were conducted based on a full factorial design. Experimental data were processed by fast Fourier transformation, regression analysis, and graphical adequate analysis. Multiple-order polynomial models were developed in order to minimise cutting force. Experimental results show that fibre orientation angle significantly influences the cutting force; furthermore, it does not have a significant effect on the passive force component, while the radial force component is more sensitive to the fibre orientation at up milling, than at down milling. An optimal condition is recommended for zig-zag milling of unidirectional CFRPs.

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Section: Comparison and Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Geier

2020

Int J Adv Manuf Technol

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“…The numerical implementation of the spring back phenomenon (partial thickness recovery of the machined surface) was found to be essential to improve the accuracy of the numerical predictions. Numerical results are validated using the experimental data collected in the trials developed by Duboust et al [44]. Interesting conclusions from the evolution of global forces to the spindle axis (F X = Horizontal force and F Y = Vertical force) and related forces to the cutting tool tooth (F T = Tangential force and F N = Normal force) are collected in this manuscript.…”

Section: Introductionmentioning

confidence: 95%

Section: Numerical Fe Model Validationmentioning

confidence: 99%

“…For the validation of this model, the average force data provided in the research of Duboust et al [44] were used. All the machining configurations tested in the machining trials developed by Duboust et al [44] with a cutting tool edge radius of 10 µm were simulated. In total, eight simulations with feed rates of 800 mm/min and 1200 mm/min, spindle speeds of 6000 rpm and 8000 rpm, and fibre orientations of 45 • and 90 • were performed.…”

Section: Numerical Fe Model Validationmentioning

confidence: 99%

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A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates

et al. 2021

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Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cutting tool significantly hinder the modelling of these types of processes. For these reasons, the numerical study of common machining operations, especially in composite machining, is still minimal. This paper presents a novel approach comprising a mixed multidirectional composite damage mode with composite edge trimming operation. An ingenious finite element framework which infer the cutting edge tool wear assessing the incremental change of the machining forces is developed. This information is essential to replace tool inserts before the tool wear could cause severe damage in the machined parts. Two unidirectional carbon fibre specimens with fibre orientations of 45∘ and 90∘ manufactured by pre-preg layup and cured in an autoclave were tested. Excellent machining force predictions were obtained with errors below 10% from the experimental trials. A consistent 2D FE composite damage model previously performed in composite machining was implemented to mimic the material failure during the machining process. The simulation of the spring back effect was shown to notably increase the accuracy of the numerical predictions in comparison to similar investigations. Global cutting forces simulated were analysed together with the cutting tool tooth forces to extract interesting conclusions regarding the forces received by the spindle axis and the cutting tool tooth, respectively. In general terms, vertical and normal forces steadily increase with tool wear, while tangential to the cutting tool, tooth and horizontal machining forces do not undergo a notable variation.

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Characterization of the cutting forces and friction behavior in machining UD-CFRP using slot milling test

Sheikh-Ahmad

Almaskari

El-Hofy

2021

Int J Adv Manuf Technol

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2D and 3D Finite Element Models for the Edge Trimming of CFRP

Cited by 12 publications

References 11 publications

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates

Characterization of the cutting forces and friction behavior in machining UD-CFRP using slot milling test

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