Numerical Modeling and FE Analysis of CFRP/Ti Stack Orthogonal Cutting

Xu, Jinyang; Mansori, Mohamed El; Voisin, Julien

doi:10.1016/j.procir.2016.03.188

Cited by 7 publications

(5 citation statements)

References 14 publications

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“…The orthogonal cutting derived from the multilayer stack drilling was designed to shed light on the underlying mechanisms behind drilling. The present work was an extension of our previous investigations under the context of CFRP/Ti6Al4V stack orthogonal cutting [3,[42][43][44][45][46]. Two different cutting sequence strategies (CFRP → Ti and Ti → CFRP) that are frequently used in the stack drilling were considered.…”

Section: Introductionmentioning

confidence: 99%

Orthogonal cutting mechanisms of CFRP/Ti6Al4V stacks

Mansori

Chen

et al. 2019

Int J Adv Manuf Technol

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The enhanced mechanical/physical properties and improved functionalities have made the carbon fiber-reinforced polymer/ titanium alloy (CFRP/Ti6Al4V) stacks very attractive to the modern aerospace industry. However, the current knowledge of machining CFRP/Ti6Al4V stacks remains insufficient to guide their industrial applications. The main contribution of the present paper lies in the scientific understanding of the coupling effects and underlying mechanisms dominating the stack chip formation and cutting response transfer via the orthogonal cutting method. A particular focus was placed on the identification of the impact of different cutting sequence strategies (i.e., cutting from CFRP to Ti6Al4V and from Ti6Al4V to CFRP) on the stack machinability. The orthogonal cutting tests were carefully performed on a shaper machine tool using the polycrystalline diamond (PCD)-tipped inserts. The present study covers a variety of aspects in the CFRP/Ti6Al4V machining including the chip removal process, cutting forces, chip features, bouncing-back phenomenon and machined surface quality. The results discussed in this work allow for a better cutting understanding of CFRP/Ti6Al4V stacks and could advance the state of knowledge of the subject area.

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Section: Introductionmentioning

confidence: 99%

Orthogonal cutting mechanisms of CFRP/Ti6Al4V stacks

Mansori

Chen

et al. 2019

Int J Adv Manuf Technol

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“…No separation zone is used in the JC damage model and therefore only one fracture energy is defined for the whole titanium phase. In fact, a separation zone is used to simplify the numerical analysis [24,26,36]. As for the cohesive bonding surface, a small thickness of the cohesive element (5 µm) was used.…”

Section: Fig 2 Mesh Generation Boundary Conditions and Geometry Of Th...mentioning

confidence: 99%

“…A direct relationship should be noted between the fracture energy, the chip morphology, and the cutting forces. It can be noticed that fragmented, segmented, or continuous chips can be obtained for three energy levels: low (<20), medium (20)(21)(22)(23)(24)(25)(26)(27)(28)(29)(30)(31)(32)(33)(34)(35) or high (>40) respectively. The cutting forces increase with increased fracture energy.…”

Section: Ti Chip Morphology Dependency To Fracture Energymentioning

confidence: 99%

“…In the literature of this field of research, only little scholar research has been conducted on the cutting process and damage formation of hybrid CFRP/Ti stacks machining. Xu et al [22,26] developed under orthogonal cutting configuration a two-dimensional finite element model to simulate machining the CFRP/Ti stack. The results showed that the cutting sequence can have a significant influence on the machined quality and induced damage in the interface region.…”

Section: Introductionmentioning

confidence: 99%

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Modeling of the interface delamination process when machining hybrid multi-material assemblies

Boutrih

Ayed

Nouari

2021

Int J Adv Manuf Technol

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Thanks to their high mechanical properties, structures involving assembled materials such as titanium/composite are suitable for many applications in aeronautical industry. However, the machining process used for these structures to achieve dimensional tolerance and assembly requirements frequently entails difficulties due to their poor machinability. A numerical model considering different phases of the assembly has been developed for machining in the present work. The behavior of the composite phase is governed by a mesomechanical model coupling the effect of the drop in stiffness, plasticity, damage initiation and its progression.The well-known thermoviscoplastic constitutive Johnson-Cook law and evolution of the damage energy criterion were considered for the titanium phase. Debonding of the CFRP/Ti interface was modeled using cohesive elements. The cutting sequence was found to be a key factor to prevent interface delamination; the cutting from Ti to CFRP phase induced permanent damage at the CFRP/Ti interface while the cutting from CFRP to Ti phase exhibits a smooth transition between phases and almost no delamination was observed. It has been also found that during the orthogonal cutting process, two levels of cutting forces related to ductile behavior for the titanium phase and brittle behavior for the composite phase, respectively. The chip formation mechanisms were correctly reproduced in comparison with experimental observations.

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“…A limited number of studies incorporating a full 3D FE model of composite machining are available to date, and mostly focussed at predicting interply delamination in orthogonal cutting application [17][18][19][20], mainly due to the extent of computational resources needed. Consequently, majority of published FE models consider 2D plane stress approximation [21][22][23][24][25][26][27][28] to analyse influence of cutting parameters on the subsurface damage. Few interesting studies and their outcomes are briefed next.…”

Section: Introductionmentioning

confidence: 99%

Effect of cutter geometry on machining induced damage in orthogonal cutting of UD polymer composites: FE study

Cepero-Mejías

Curiel-Sosa

Zhang

et al. 2019

Composite Structures

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This article presents a finite-element analysis (FEA) based study to understand the influence of cutting parameters (rake angle, relief angle and cutter edge radius) on the machining-induced damage of unidirectional (UD) composites. Carbon/epoxy (CFRP) and glass/epoxy (GFRP) composites are considered. Onset of damage in composites is modelled using a combination of maximum stress and Puck's fracture criteria, while a novel damage propagation algorithm is proposed to account for the post-damage material softening behaviour. A spring-back phenomenon (partial elastic recovery of workpiece material after tool passed a cutting surface) often observed in composites machining, is considered in the FE model to allow a better prediction of the thrust force and induced damage. A validated FE model predicts that with increasing relief angle, the extent of sub-surface damage is reduced. Rake angle or tool edge radius are not found to have a great influence on the induced damage. A large dependence is observed between the fibre angle and the induced damage, as the severity of damage increase when fibre orientations varies from 30 • to 90 • .

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Numerical Modeling and FE Analysis of CFRP/Ti Stack Orthogonal Cutting

Cited by 7 publications

References 14 publications

Orthogonal cutting mechanisms of CFRP/Ti6Al4V stacks

Orthogonal cutting mechanisms of CFRP/Ti6Al4V stacks

Modeling of the interface delamination process when machining hybrid multi-material assemblies

Effect of cutter geometry on machining induced damage in orthogonal cutting of UD polymer composites: FE study

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