Finite Element Analysis of Drilling of Carbon Fibre Reinforced Composites

Abstract

Despite the increased applications of the composite materials in aerospace due to their exceptional physical and mechanical properties, the machining of composites remains a challenge. Fibre reinforced laminated composites are prone to different damages during machining process such as delamination, fibre pull-out, microcracks, thermal damages. Optimization of the drilling process parameters can reduces the probability of these damages. In the current research, a 3D finite element (FE) model is developed of the process of drilling in the carbon fibre reinforced composite (CFC). The FE model is used to investigate the effects of cutting speed and feed rate on thrust force, torque and delamination in the drilling of carbon fiber reinforced laminated composite. A mesoscale FE model taking into account of the different oriented plies and interfaces has been proposed to predict different damage modes in the plies and delamination. For validation purposes, experimental drilling tests have been performed and compared to the results of the finite element analysis. Using Matlab a digital image analysis code has been developed to assess the delamination factor produced in CFC as a result of drilling.

Mechanical load distribution along the main cutting edges in drilling

“…A recent study (Isbilir and Ghassemieh, 2011) attempt the simulation of the complete drilling process for uni-directional CFRP composites using a 8 mm twist drill. For their model validation one experimental case is compared with the simulation results showing the prediction capabilities of Fig.…”

“…Simple empirical modeling of the cutting forces would not allow differentiating between different drill geometries, while currently available mechanistic models are not calibrated or discussed against experimental information of the forces distribution. FEM models to calculate the thrust and torque forces are reported as taking too much time (4 months for a complete drilling process run - Isbilir and Ghassemieh, 2011).…”

“…Comparison between experimental and predicted results of the current model,Chandrasekharan et al (1995) andIsbilir and Ghassemieh (2011).…”

Investigation of experimental study of end milling of CFRP composite

“…However, the milling of composite components remains a challenge. There have been several studies in the literature on damage, surface roughness, and cutting forces in milling of CFRP composites [5][6][7]. Hocheng et al [8] presented a preliminary scientific study on the milling of CFRP composites.…”

Meso-scale Modeling of the Drilling of Carbon Fibre Reinforced Plastic: Geometry and Numerical Analysis

“…Polynomial maximum stress criterion, Polynomial maximum strain criterion, Tsai, Tsai-Hill, Tsai-Azzi, Hoffman, Tsai-Wu and Hashin criteria are the examples of the polynomial failure criteria. In all these criteria, there is dependence between the components in each direction [18,19].…”