Abstract
Finite element (FE) simulation is a powerful tool for investigating the mechanism of machining fiber-reinforced polymer composite (FRP). However in existing FE machining simulation works, the two-dimensional (2D) progressive damage models only describe material behavior in plane stress, while the three-dimensional (3D) damage models always assume an instantaneous stiffness reduction pattern. So the chip formation mechanism of FRP under machining is not fully analyzed in general stress state. A 3D macro-mechanical based FE simulation model was developed for the machining of unidirectional glass fiber reinforced plastic. An energy based 3D progressive damage model was proposed for damage evolution and continuous stiffness degradation. The damage model was implemented for the Hashin-type criterion and Maximum stress criterion. The influences of the failure criterion and fracture energy dissipation on the simulation results were studied. The simulated chip shapes, cutting forces and sub-surface damages were verified by those obtained in the reference experiment. The simulation results also show consistency with previous 2D FE models in the reference. The proposed research provides a model for simulating FRP material behavior and the machining process in 3D stress state.
Highlights
Fiber reinforced polymer composite (FRP) material is finding increasing applications in modern aerospace, automobile and sports industries
A significant amount of machining work is necessary as material removal is required for the FRP component to meet the dimensional requirements before assembly
In the 2D finite element (FE) model developed by Lasri et al [17], damage analysis was conducted using the Hashin, Maximum stress and Hoffman failure criteria together with the instantaneous stiffness degradation strategy
Summary
Fiber reinforced polymer composite (FRP) material is finding increasing applications in modern aerospace, automobile and sports industries. In the 2D FE model developed by Lasri et al [17], damage analysis was conducted using the Hashin, Maximum stress and Hoffman failure criteria together with the instantaneous stiffness degradation strategy. In the meso-scale CFRP drilling FE models developed by Isbilir et al [24] and Feito et al [25], sudden stiffness degradation was assumed in intra-lamina failure analysis with the 3D Hashin and Hou criteria, respectively. The FRP material behavior during cutting is not fully investigated in a general stress state, because the 2D damage model is only applicable with plane stress assumption. An energy based progressive damage model was proposed with the Hashin-type and Maximum stress criteria for continuous stiffness degradation of UD-GFRP. The proposed damage model can be used in FRP structure analysis (e.g., under low-velocity impact load)
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