Review of recent developments and induced damage assessment in the modelling of the machining of long fibre reinforced polymer composites

Cepero-Mejías, F.; Curiel-Sosa, J.L.; Blázquez, Antonio; Yu, Tiantang; Kerrigan, Kevin; Phadnis, Vaibhav A.

doi:10.1016/j.compstruct.2020.112006

Cited by 53 publications

(15 citation statements)

References 87 publications

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“…The finite element method (FEM) having a strong cost advantage over experiments was considered to be a powerful tool for modeling machining process, 25,26 and brought great convenience to the study of residual stress. Due to the existence of reinforcements, the rupture process of composite is more complicated and cannot be effectively observed, thus using finite element method is conducive to better understand related characteristics.…”

Section: Introductionmentioning

confidence: 99%

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Wang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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High-efficient machining of SiC particles reinforced composites is always challenging mainly due to their poor surface integrity. In this study, a two-phase finite element model including the Al alloy matrix with Johnson-Cook model and SiC particle with elastic-brittle failure model were developed. The main purpose is to comprehensively investigate particle removal mechanisms and surface integrity following simulation and experimental studies on milling SiCp/Al composites. Specifically, the distributions of residual stress along the depth direction were predicted using finite element model. Results indicated that compressive residual stress mainly appeared on the machined surface, while tensile residual stress distributed at deeper depth down to 0.02 mm. Besides, different relative positions between tool and particle induced specific particle removal modes, which eventually led to various surface defects. Higher level of cutting speed (180 m/min) and feed rate (0.09 mm/tooth) aggravated surface defects and increased the thickness of broken-SiC layer in subsurface. The simulated machined surface defects and surface residual stress correlated well with the experimental observation, and the maximum error value of cutting force was less than 15%. The proposed finite element model was efficient to predict cutting force and distribution of residual stress along the depth direction.

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Section: Introductionmentioning

confidence: 99%

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Wang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Apparent COF (ACOF) values and material-linked friction models in metal cutting simulations have been studied more extensively than CFRP materials [ 9 ]. Due to the lack of stick–slip contact mechanism in CFRP machining, chip formation characteristics and the complex anisotropic material structure of CFRPs, no comparisons can be made between metallic and composite machining approaches or simulation strategies [ 10 ]. Frictional effects on secondary valuation criteria, such as temperature and frictional energy in CFRPs, have been known to be an area of concern for many years [ 11 ].…”

Section: Introductionmentioning

confidence: 99%

Development of a Novel Friction Model for Machining Simulations in Unidirectional Composite Materials

et al. 2022

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Constant coefficients of friction (COFs) are currently used in the literature to describe the contact mechanics between tool and workpiece for finite element (FE) machining simulation of carbon fibre-reinforced polymers (CFRPs). However, these are solely based on closed-loop tribology experimentation, which insufficiently represent machining conditions. To overcome this gap in the knowledge, this work proposes a novel experimental open-loop tribological testing method to produce a dynamic FE friction model for CFRP machining simulations. The newly proposed dynamic friction model is based on a function of fibre angle, contact pressure and slip rate, and it has been validated to both experimental results and constant COF FE simulations. The main aim of this article is to create a link between machining, tribology and FE simulation, by implementing cutting-edge tribological testing that results in highly accurate FE simulations. This dynamic model has been shown to improve the accuracy of open-loop tribological simulations, giving confidence in future implantation in CFRP machining simulations.

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“…[7]. Due to their anisotropic and non-homogeneous characteristics as well as to the highly abrasive nature of their fibres, especially for GFRP [8], composites are difficult-tomachine materials. High abrasive wear effects on the cutting tools are observed, as well as failures in laminates during the process.…”

Section: Introductionmentioning

confidence: 99%

Sensitivity Analysis of Various Geometries of PCD and Cemented Tungsten Carbide Cutting Tools during the Milling of GFRP Composite

et al. 2022

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Although much research has been carried out in the field of the milling of GFRP (Glass Fibre Reinforced Polymer) composites, the complexity of the process is such that it is still not mastered in many industrial cases. The current work is aimed at studying the influence of three different geometries of PCD (PolyCrystalline Diamond) and cemented tungsten carbide cutting tools during the up-milling of GFRP composites at fixed cutting conditions (vc = 502 m/min and vf = 420 mm/min). Delamination, cutting forces and tool wear are compared at the fresh and worn states, and the correlation between the lifespan and the cost of the cutting tool is analysed. The main wearing phase of the tools was performed under the conditions of production in the facilities of a company (Sobelcomp, Loncin, Belgium). The results indicate that the PCD tool with the straight edge, inclined peripheral tooth shape produces the smallest total cutting force and less delamination (shortest and lowest number of delaminated fibres) at both fresh and worn states. Moreover, the grinding ability of PCD makes the cutting tool cost per part lower than for cemented carbide. The PCD tool is therefore the best option to mill GFRP parts.

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Review of recent developments and induced damage assessment in the modelling of the machining of long fibre reinforced polymer composites

Cited by 53 publications

References 87 publications

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Modeling and experimental study on tool-particle interaction and surface integrity in milling SiCp/Al metal matrix composites

Development of a Novel Friction Model for Machining Simulations in Unidirectional Composite Materials

Sensitivity Analysis of Various Geometries of PCD and Cemented Tungsten Carbide Cutting Tools during the Milling of GFRP Composite

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