Out-of-plane failure mechanisms in LFRP composite cutting

Abstract

Damage Out-of-plane failure LFRP (Long Fiber Reinforced) composites are widely used in structural components for high responsibility applications in different industrial sectors. Composite components are manufactured near final shape, however several machining operations are commonly required to achieve dimensional and assembly specifications. Machining should be carefully carried out in order to avoid workpiece damage. Despite of the interest of numerical modeling to analyze in detail the phenomena involved during composite cut ting, there are only few works in the scientific literature dealing with this topic even in the simple case of orthogonal cutting. Out of plane failure can be accounted only if three dimensional modeling is per formed. However up to date numerical analysis of cutting found in scientific literature was focused in two dimensional approach. In this paper (2D) and three dimensional (3D) numerical modeling of orthog onal cutting of carbon LFRP composite are presented. The aim of the paper is to analyze the complex aspects involved during cutting, including out of plane failure.

Meshfree formulation for modelling of orthogonal cutting of composites

“…Studies that used the steady state approach include [8][9][10][11][12][13]. Some studies that adopted the transient approach include [14][15][16][17][18][19][20].…”

“…Some studies [8][9][10] combined two failure mechanisms, primary failure for the onset of chip formation and a secondary failure for the progressive failure and completion of chip formation. The progressive failure was modelled through stiffness degradation concept [11] or continuum damage mechanics approach [15][16][17] .…”

The influence of anisotropy in numerical modeling of orthogonal cutting of cortical bone

“…Two different models were developed: 2D for isotropic behaviour and 3D allowing the simulation of different orientations of the osteons. In the second model recent results obtained by the authors in composite cutting were considered, such as the influence of fibre orientation on chip morphology [19] and the prediction of temperature distribution [20]. Interesting conclusions were obtained, finding a strong influence of the anisotropy in chip morphology and temperature.…”

“…The use of wedge elements (prismatic element with triangular section) minimizes the dependence of the results with mesh orientation. A mesh sensibility analysis was carried out in previous work by the authors [19,20]). Therefore, it was set a minimum element size around the cutting zone equal to 7 lm showing reasonably accuracy and computational cost.…”

A review on recent advances in numerical modelling of bone cutting

“…Among these factors the most important and complex one is the constitutive model of the bone. Even in the well-known case of metal or composite cutting operations, accurate modelling of mechanical behaviour of the workpiece is crucial for machining simulation, see for instance the recent works of the authors (Miguélez et al, 2013;Santiuste et al, 2011). These applications are good examples of isotropic (metal) and anisotropic (composite) workpieces.…”