Session: 02-09-03: Computational Modeling and Simulation for Advanced Manufacturing-III

Paper Number: 73310

Start Time: Tuesday, 04:10 PM

73310 - Numerical Investigation Into the Cutting Forces, Chip Formation Mechanism, and Burr Formation During Slot Milling of Laminated CFRP Composites 

Carbon Fiber Reinforced Polymer (CFRP) composites have been attracting wide attention to industrial applications, such as in aerospace and automotive industries, because of their superior specific strength/ stiffness, excellent damage tolerance and fatigue life, and outstanding corrosion resistance along with their distinguished thermal and acoustic insulation capacity.  The availability of laminated CFRP sheets has made it easy to manufacture many complex shapes accompanied by these wonderful properties. As the additive manufacturing technology has been evolving, laminates of different sorts including CFRP composites have been made possible. Machining (post-processing) the laminated CFRP workpiece is of great importance, as it helps to achieve the desired shapes along with the desired dimensional accuracy. In this research, ABAQUS, a powerful commercial finite element method (FEM) software package, is utilized to model and simulate the milling of CFRP composites for post processing. The effect of machining parameters (spindle speed, feed rate, and depth of cut) has been assessed in terms of stress distribution, temperature distribution, cutting forces, chip formation, and material removal mechanisms. In this research, coupled temperature-displacement elements are used in order to capture the effect of machining on both deformation and temperature distribution. Several constitutive and damage models have been used and the best one has been selected. A slot milling tool is designed using Autodesk Inventor and the material properties of cemented carbide (WC-Co) are specified to this deformable tool. 15 laminates are assembled together using quadratic damage cohesive model. Two different fiber orientations (0 degree and 45 degree) have been tested. A rigid plate is modeled and attached to the bottom face of the bottom laminate and the reference point of this rigid plate is used to capture the history of cutting forces in three directions. This study also aims to model chip and burr formation during milling of CFRP laminates. The reinforced laminates make the layers to be transversely isotropic in characteristics. With the change of angle of reinforcements, the CFRP characteristics changes, and so as the chip formation mechanisms. The chip formation is influenced by the rigidity of the tool, cutting tool geometry, fiber reinforcement directions, and laminate workpiece properties. The modeling and simulation of machining CFRP composites considers failure mechanisms of fibers and matrix of composites that are different than traditional metal machining. Finally, the simulation results reveal that the ABAQUS FEM model can predict the cutting forces in three directions, stress and temperature distributions, chip formation and burr formation.

Presenting Author: M. P. Jahan Miami University

Authors:

Md Mahmudul Hassan Miami University
Jeff Ma Saint Louis University
M. P. Jahan Miami University