Study on Damage Evaluation and Machinability of UD-CFRP for the Orthogonal Cutting Operation Using Scanning Acoustic Microscopy and the Finite Element Method.

Dongyao Wang,Xiaodong He,Linlin Li,Zhonghai Xu,Rongguo Wang,Long Jiang,Wenbo Liu,Weicheng Jiao,Fan Yang

doi:10.3390/ma10020204

Abstract

Owing to high specific strength and designability, unidirectional carbon fiber reinforced polymer (UD-CFRP) has been utilized in numerous fields to replace conventional metal materials. Post machining processes are always required for UD-CFRP to achieve dimensional tolerance and assembly specifications. Due to inhomogeneity and anisotropy, UD-CFRP differs greatly from metal materials in machining and failure mechanism. To improve the efficiency and avoid machining-induced damage, this paper undertook to study the correlations between cutting parameters, fiber orientation angle, cutting forces, and cutting-induced damage for UD-CFRP laminate. Scanning acoustic microscopy (SAM) was employed and one-/two-dimensional damage factors were then created to quantitatively characterize the damage of the laminate workpieces. According to the 3D Hashin’s criteria a numerical model was further proposed in terms of the finite element method (FEM). A good agreement between simulation and experimental results was validated for the prediction and structural optimization of the UD-CFRP.

Highlights

Unidirectional carbon fiber reinforced polymer (UD-CFRP) has been widely used in various fields including aviation, spaceflight, shipping, and structural engineering, owing to its superior performance of high specific strength, high specific stiffness, fatigue resistance, and damage tolerance [1,2,3]
Chip formation of unidirectional carbon fiber reinforced polymer (UD-CFRP) possesses the features of discontinuity and irregularity compared with conventional metal materials; more expensive tools, the polycrystalline diamond (PCD) tool, the PCD-coated tool or the cubic boron nitride (CBN) tool, are commonly utilized in machining UD-CFRP to replace the conventional high-speed-steel tool for mitigating tool wear [8]
To study the machining mechanism of the orthogonal cutting process of UD-CFRP, experiments andmachining the finite element method haveorthogonal been both carried to assess the effect experiments of cutting To study the mechanism of the cutting out process of UD-CFRP, parameters and fiber orientations on cutting forces and cutting induced damage

Summary

Introduction

Unidirectional carbon fiber reinforced polymer (UD-CFRP) has been widely used in various fields including aviation, spaceflight, shipping, and structural engineering, owing to its superior performance of high specific strength, high specific stiffness, fatigue resistance, and damage tolerance [1,2,3]. Conventional metal materials are gradually being replaced by UD-CFRP in the majority of modern industries and in some traditional structural engineering fields [4]. Three major individual components of fiber, matrix, and fiber-matrix interface are incorporated in a UD-CFRP. Chip formation of UD-CFRP possesses the features of discontinuity and irregularity compared with conventional metal materials; more expensive tools, the polycrystalline diamond (PCD) tool, the PCD-coated tool or the cubic boron nitride (CBN) tool, are commonly utilized in machining UD-CFRP to replace the conventional high-speed-steel tool for mitigating tool wear [8]

Methods

Results

Conclusion