Evaluation of heat generation using a microscopic cutting model with thermo-mechanical coupling for carbon fiber reinforced polymer composites

Qian, Miao; Xiao, Jianzhang; Wang, Guifeng; Huang, Pengcheng; Chen, Zhongzhe; Han, Gaorong

doi:10.1177/0731684420931589

Cited by 6 publications

(10 citation statements)

References 31 publications

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“…FRP machining e.g., [9][10][11][12]14,15,[32][33][34][35]. However, significant deficiencies in thermomechanical modeling of new hybrid composites still exist.…”

Section: Heat Dissipatedmentioning

confidence: 99%

Towards an Advanced Modeling of Hybrid Composite Cutting: Heat Discontinuity at Interface Region

et al. 2023

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In this study, a thermomechanical model is developed to simulate a finite drilling set of Carbon Fibre Reinforced Polymers (CFRP)/Titanium (Ti) hybrid structures widely known for their energy saving performance. The model applies different heat fluxes at the trim plane of the two phases of the composite, owing to cutting forces, in order to simulate the temperature evolution at the workpiece during the cutting step. A user-defined subroutine VDFLUX was implemented to address the temperature-coupled displacement approach. A user-material subroutine VUMAT was developed to describe Hashin damage-coupled elasticity model for the CFRP phase while Johnson–Cook damage criteria was considered for describing the behavior of titanium phase. The two subroutines coordinate to evaluate sensitively the heat effects at the CFRP/Ti interface and within the subsurface of the structure at each increment. The proposed model has been first calibrated based on tensile standard tests. The material removal process was then investigated versus cutting conditions. Predictions show discontinuity in temperature field at interface that should further favor damage to localize especially at CFRP phase. The obtained results highlight the significant effects of fibre orientation in dominating cutting temperature and thermal effects over the whole hybrid structure.

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“…FRP machining e.g., [9][10][11][12]14,15,[32][33][34][35]. However, significant deficiencies in thermomechanical modeling of new hybrid composites still exist.…”

Section: Heat Dissipatedmentioning

confidence: 99%

Towards an Advanced Modeling of Hybrid Composite Cutting: Heat Discontinuity at Interface Region

et al. 2023

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“…The resin surface temperature is higher because the thermal conductivity of the resin is low. Sheikh-Ahmad et al [94] proposed that inverse heat conduction method was an effective and efficient technique for determining the energy balance in machining CFRP. Qian et al [95] found that the heat generation mechanism at 90° was more complex compared with 0°, resulting in the highest cutting temperature when the FCA was 90°.…”

Section: Thermal and Mechanical Behaviormentioning

confidence: 99%

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

et al. 2022

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Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

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“…[19][20][21] To examine the detail information of subsurface damage, various experimental observation technologies have been used, such as the application of the X-ray tomography, optical and electron microscopy techniques. [22][23][24][25] On the other hand, as the development of modeling tools, prediction of machining-induced damage in composite cutting has been commonly achieved using finite element method (FEM). Wang et al 26 studied the influences of machining parameters on surface subsurface damage by using the finite element modeling in CFRP cutting.…”

Section: Introductionmentioning

confidence: 99%

“…19-21 To examine the detail information of subsurface damage, various experimental observation technologies have been used, such as the application of the X-ray tomography, optical and electron microscopy techniques. 22-25…”

Section: Introductionmentioning

confidence: 99%

A study of surface integrity in carbon fiber-reinforced polymer composites cutting with the coupling effect of the multiple machining parameters

Xiao

Wang

Su³

et al. 2022

Journal of Composite Materials

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In the paper, a three-dimensional (3D) micromechanical numerical cutting model with three phases was developed to study the surface integrity in cutting of Carbon fiber-reinforced polymer (CFRP) composites. The surface roughness and the depth of subsurface damage were predicted by using the numerical model, which were used to characterize the surface integrity. The machined surface observations and surface roughness measurements of CFRP composites at different fiber orientations were also performed for model validation. It is indicated that the 3D micromechanical cutting model is capable of precisely predicting the surface integrity of CFRP composites. To investigate the complex coupling influences of multiple machining parameters on the surface integrity, the factor analysis of multiple machining parameters was performed, and then the effects of these machining parameters on the surface roughness and subsurface damage depth were obtained quantitatively. It was found that the coupling effect of fiber orientation and cutting speed are the most significant factors to affect the surface roughness with the contribution rate of 4.8%, and the interaction between fiber orientation and edge radius has the most important effect on the subsurface damage depth with the rate of 5%. The results also reveal that coupling effects of cutting speed and rake angle should be considered for improving the surface integrity of CFRP composites.

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Evaluation of heat generation using a microscopic cutting model with thermo-mechanical coupling for carbon fiber reinforced polymer composites

Cited by 6 publications

References 31 publications

Towards an Advanced Modeling of Hybrid Composite Cutting: Heat Discontinuity at Interface Region

Towards an Advanced Modeling of Hybrid Composite Cutting: Heat Discontinuity at Interface Region

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

A study of surface integrity in carbon fiber-reinforced polymer composites cutting with the coupling effect of the multiple machining parameters

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