Tailoring fiber arrangement in subsurface damage layer of unidirectional CFRP composites by reverse multi-pass cutting

Han, La; Zhang, Jun Jie; Sun, Tao

doi:10.1016/j.compscitech.2022.109571

Cited by 13 publications

(1 citation statement)

References 56 publications

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“…In addition, the use of a large number of cutting steps accompanied by a small DOC for material removal is beneficial for achieving the ultra-high surface quality of composites. Compared with the single-pass strategy, the multi-pass strategy is also beneficial for improving the machined surface quality of unidirectional CFRP and SiCp/Al in orthogonal cutting [132][133][134]. Specifically, under the condition of the same total DOC, the use of multi-pass cutting strategies can reduce the surface roughness and subsurface damage, as shown in figure 8(c).…”

Section: Synergetic Deformation Behavior Of Composite Materialsmentioning

confidence: 99%

Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook

Zhao

Zhang

et al. 2023

Int. J. Extrem. Manuf.

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Ultra-precision diamond cutting is a promising machining technique for realizing ultra-smooth surface of different kinds of materials. While fundamental understanding of the impact of workpiece material properties on cutting mechanisms is crucial for promoting the capability of the machining technique, numerical simulation methods at different length and time scales act as important supplements to experimental investigations. In this work, we present a compact review on recent advancements in the numerical simulations of material-oriented diamond cutting, in which representative machining phenomena are systematically summarized and discussed by multiscale simulations such as molecular dynamics simulation and finite element simulation: the anisotropy cutting behavior of polycrystalline material, the thermos-mechanical coupling tool-chip friction states, the synergetic cutting responses of individual phase in composite materials, and the impact of various external energetic fields on cutting processes. In particular, the novel physics-based numerical models, which involve the high precision constitutive law associated with heterogeneous deformation behavior, the thermo-mechanical coupling algorithm associated with tool-chip friction, the configurations of individual phases in line with real microstructural characteristics of composite materials, and the integration of external energetic fields into cutting models, are highlighted. Finally, insights into the future development of advanced numerical simulation techniques for diamond cutting of advanced structured materials are also provided. The aspects reported in this review present guidelines for the numerical simulations of ultra-precision mechanical machining responses for a variety of materials.

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Section: Synergetic Deformation Behavior Of Composite Materialsmentioning

confidence: 99%

Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook

Zhao

Zhang

et al. 2023

Int. J. Extrem. Manuf.

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Effects of grinding mode on grinding performance of anisotropic CF/PEEK composites

Yan,

Zhao,

et al. 2024

Polymer Composites

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Grinding could be used to enhance accuracy and quality of carbon fiber‐reinforced poly‐ether‐ether‐ketone (CF/PEEK) composites. However, the grinding mode, namely up‐grinding (UG) or down‐grinding (DG), is usually neglected while unbefitting grinding mode choice may cause inferior surface quality. To investigate effects of grinding modes on grinding performance of anisotropic CF/PEEK, grinding experiments in UG and DG were carried out under different fiber orientation angles θ. Experimental results indicated that maximum grinding temperatures and normal grinding forces in UG were lower than DG regardless of the abrasive grit sizes. Material removal mechanisms of CF/PEEK affected by grinding mode were revealed by analyzing morphologies of surface, chip and grinding wheel. When θ = 0°, the dominant mechanisms in DG were extrusion fracture and fiber deformation, while they were interface shear debonding and bending fracture in UG. When θ = 90°, the dominant mechanisms in DG included interface layer separation and bending fracture, while they were shear and extrusion fracture of well‐supported fibers in UG. Thus, UG was more favorable for material removal, obtaining lower surface roughness values, fewer machining defects and less wheel wear than DG. This study will provide technical guidance for high‐quality grinding of carbon fiber‐reinforced thermoplastic composites.Highlights The effects of grinding modes (DG and UG) on the grinding performance of anisotropic CF/PEEK composites were investigated. Material removal mechanisms of CF/PEEK affected by grinding mode were revealed under different fiber orientation angles. The maximum grinding temperatures and normal grinding forces in UG were lower than DG. UG was more favorable for material removal in grinding, and could produce better ground surface quality than DG.

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Solutions and applications of fracture properties for clamped single edge notched tensile specimen of orthotropic materials

Wang,

Jin,

Chen

et al. 2024

Polymer Composites

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Clamped single edge notched tensile (SENT) specimens are widely used in fracture toughness test and fatigue crack growth experiment of structural materials. However, the existing fracture parameters of clamped SENT specimens are all based on isotropic conditions, which limits the application of anisotropic materials. In this study, a systematic finite element analysis of orthotropic clamped SENT specimens was carried out to determine the stress intensity factor (K) and compliance (C). A wide range of orthotropic and geometric parameters, including crack length over width ratio (a/W), daylight to width ratio (H/W), and material parameters λ and ρ, were considered. The coupling effects of material parameters and geometrical dimensions on fracture properties were then investigated. Results showed that the K and C increase with the increase of a/W and H/W, and decrease with the increase of λ and ρ. The value of C is more sensitive to changes of orthotropic and geometric parameters than the K. Moreover, the accurate solutions for normalized K, C and compliance‐based crack length prediction were developed. Applications of the proposed solutions on experimental data were presented and discussed. The current results will help to accurately calculate the fracture toughness or FCG rate of composites, further advancing the standardization process of composites testing based on SENT specimens.Highlights Evaluate the K and Compliance for orthotropic single edge notched tensile (SENT) specimens using 2D finite element analysis; The coupling effects of orthotropic parameters and geometric sizes are studied; Develop prediction equations for K and C of clamped SENT specimen; Propose a universal crack length estimation method based on the compliance; Discuss the application of the proposed equations to the tested data of UD CFRP.

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Tailoring fiber arrangement in subsurface damage layer of unidirectional CFRP composites by reverse multi-pass cutting

Cited by 13 publications

References 56 publications

Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook

Numerical simulation of materials-oriented ultra-precision diamond cutting: review and outlook

Effects of grinding mode on grinding performance of anisotropic CF/PEEK composites

Solutions and applications of fracture properties for clamped single edge notched tensile specimen of orthotropic materials

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