A review on finite element method for machining of composite materials

Shetty, Nagaraja; Shahabaz, S. M.; Sharma, Sathyashankara; Shetty, S. Divakara

doi:10.1016/j.compstruct.2017.06.012

Cited by 109 publications

(38 citation statements)

References 120 publications

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“…Nevertheless, if we consider that the peak value of the perforation force is crucial information in the punch optimization, we can consider the presented model as useful enough. This approach was previously presented in [2,3] and the obtained results have proved that considering the composite as an equivalent homogenous material in FEM analyses may be used in this application and it was supported with multiple examples found in scientific literature [23][24][25][26][27][28][29][30][31]. However, using only FEM analyses may give some false results connected with the mesh or poorly chosen failure parameters, which is why authors used a combination of both methods of research in which the experimental tests results are used for model verification.…”

Section: Influence Of the Geometrical Features Of The Punch And Die Osupporting

confidence: 65%

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Determination of the effective geometrical features of the piercing punch for polymer composite belts

Wojtkowiak

Talaśka

2019

Int J Adv Manuf Technol

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Punch optimization is important in improving the technological process of belt perforation. Research about this process can rarely be found in the scientific literature. The objective of this paper is to determine the effective geometry of the piercing punches with a spherical bowl used for polymer composite belts. In order to fulfill this goal, the complex research of the influence of the geometrical features of the piercing punch on the perforation force, the hole quality, and the tool life has been conducted. For derivation of the proposed model, the authors have used the combination of analytical and FEM analyses, along with the experimental tests validation. Based on the results, there are clear correlations between the depth of the spherical bowl punch and the perforation force or the hole diameter deviation. By analyzing the ratio of the perforation and transverse force, we are able to evaluate how the tool life will change for different sets of geometrical parameters. All these correlations have been used to derive the indicators of the perforation force, tool life, and hole quality. Based on those, the optimization function has been specified. Finding the minimum value of this function makes it possible to define the optimal tool geometry. The design of effective tools for belt perforation with diameters D = 5, 6, 8, and 10 mm has been presented, but the obtained characteristic makes it possible to find an optimal solution for any diameter which lays in the range from 3 to 10 mm. Since the model has been built based on the indicators, it is easy to adjust it to match any specific requirements of the belt manufacturers, which makes it useful for tool designers.

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Section: Influence Of the Geometrical Features Of The Punch And Die Osupporting

confidence: 65%

“…It can be achieved by using the critical values of tool life F P F T cr , hole diameter deviation Δ cr or the maximum drive force F D and the expanded model is presented as Eqs. [25][26][27].…”

Section: Optimization Of the Punch Geometrymentioning

confidence: 99%

Determination of the effective geometrical features of the piercing punch for polymer composite belts

Wojtkowiak

Talaśka

2019

Int J Adv Manuf Technol

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“…Another reason of the inaccuracy is considering the composite material to be equivalent homogenous one [45]. However, it was proven that machining simulations for composites can be made based on an equivalent homogenized modeling [46].…”

Section: Validation Of the Analytical Model With Using Fem Analysesmentioning

confidence: 99%

Estimation of the perforation force for polymer composite conveyor belts taking into consideration the shape of the piercing punch

Wojtkowiak

Talaśka

Malujda

et al. 2018

Int J Adv Manuf Technol

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Due to the improvement of the mechanical properties of polymer composite belts used in vacuum belt conveyors, its perforation process causes a lot of technical issues for manufacturers worldwide. The objective of this paper is to analyze the belt punching process with two cutting edges and present the influence of the piercing punch shape on the perforation force. Based on the analysis, the analytical stress model was derived and validated by using both empirical and FEM tests. The application of the proposed model was proved by presenting the methodology used to estimate the perforation force for the flat piercing punch based on the mechanical properties of the belt obtained from simple strength tests (uniaxial tension, compression, and shear), with an error between 4 and 15%. In this report, the analysis of the piercing punch profiles was made and eight different piercing punch profiles were tested. Presented results confirmed that the spherical bowl punch may be considered as a most effective tool for belt punching, because it reduced the perforation force by 60% and the precision of the created holes was the best among the tested punch profiles for all three groups of polymer composite belts. By combining the obtained results, in the form of shape factors β, with the perforation force approximation model, it is possible to calculate peak force value for the specified tool profile and belt type and use this data in the design process of the punching dies.

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“…In addition, the related parameters can be easily changed. However, it is difficult to establish a simulation model due to the anisotropy of the composite [11,12]. At present, the numerical simulation model for the CFRP composites can be divided into two categories: macro and micro models.…”

Section: Introductionmentioning

confidence: 99%

Micro Model of Carbon Fiber/Cyanate Ester Composites and Analysis of Machining Damage Mechanism

Liu

Jiao

Sun

et al. 2019

Chin. J. Mech. Eng.

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Machining damage occurs on the surface of carbon fiber reinforced polymer (CFRP) composites during processing. In the current simulation model of CFRP, the initial defects on the carbon fiber and the periodic random distribution of the reinforcement phase in the matrix are not considered in detail, which makes the characteristics of the cutting model significantly different from the actual processing conditions. In this paper, a novel three-phase model of carbon fiber/cyanate ester composites is proposed to simulate the machining damage of the composites. The periodic random distribution of the carbon fiber reinforced phase in the matrix was realized using a double perturbation algorithm. To achieve the stochastic distribution of the strength of a single carbon fiber, a novel method that combines the Weibull intensity distribution theory with the Monte Carlo method is presented. The mechanical properties of the cyanate matrix were characterized by fitting the stress-strain curves, and the cohesive zone model was employed to simulate the interface. Based on the model, the machining damage mechanism of the composites was revealed using finite element simulations and by conducting a theoretical analysis. Furthermore, the milling surfaces of the composites were observed using a scanning electron microscope, to verify the accuracy of the simulation results. In this study, the simulations and theoretical analysis of the carbon fiber/cyanate ester composite processing were carried out based on a novel three-phase model, which revealed the material failure and machining damage mechanism more accurately.

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A review on finite element method for machining of composite materials

Cited by 109 publications

References 120 publications

Determination of the effective geometrical features of the piercing punch for polymer composite belts

Determination of the effective geometrical features of the piercing punch for polymer composite belts

Estimation of the perforation force for polymer composite conveyor belts taking into consideration the shape of the piercing punch

Micro Model of Carbon Fiber/Cyanate Ester Composites and Analysis of Machining Damage Mechanism

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