Study on cutting force and induced thermal damage of carbon fiber reinforced polymer composites using microscopic simulation modeling

Abstract

A three-dimensional (3D) microscopic finite element (FE) cutting model was developed with the thermo-mechanical coupling for carbon fiber reinforced polymer (CFRP) composites in this article. The model predictions of cutting force, machined surface, and cutting temperature at various fiber orientations were obtained and compared with the experimental data. It was shown that the 3D microscopic cutting model can predict the cutting force, cutting temperature, and subsurface damage precisely. The behavior of cutting force has presented an obviously cyclical variation characteristics at the fiber orientations of 0 , 45 , and 90 , and different chip morphologies were obtained correspondingly. The temperature fields of machined surface were studied at the four different fiber orientations, in which the maximum residual temperature on the machined surface occurs at 90 . The heat-induced resin coating and resin ridges on the machined surface were obviously observed at the fiber orientations of 45 and 135 . The trend curve of cutting temperature is more similar with that of thrust force by comparing with cutting force, which meaning, unlike the isotropic metal materials, the thrust force has the direct effect on the heat generation. In addition, the comparison of depth of thermal and mechanical subsurface damage was also performed, it was showed that the depths of thermal subsurface damage are close to that of mechanical subsurface damage in the range of 0 -45 , and the thermal subsurface damage decrease while the mechanical subsurface damage increases with the increase of the fiber orientation range from 90 to 180 .

Grinding performance study of CF/epoxy and CF/PEEK composites

“…[11] Although CFRP is mostly processed by the near-net shapes methods such as filament winding, autoclave molding or compression molding, secondary machining operation is often necessary to meet stringent assembly requirements in terms of dimensional tolerance and surface quality. [12] Such as cutting, [13][14][15][16] milling, [17,18] drilling, [19] abrasive water jet, [20] ultrasonic machining, [21] etc. However, because the structure of CFRP composites is anisotropic, and the interfacial performance between carbon fiber (CF) and resin is poor, [3,5] the above machining methods are prone to surface damages such as delamination, fiber-matrix interface debonding, pulling out of the fiber and matrix cracking.…”

Study on anisotropic heat transfer and thermal damage in nanosecond pulsed laser processing of CFRP

“…The finite element analysis (FEA) method is an effective way to investigate the HAZ, the heat transfer, and the machining mechanism. 24,25 Yang et al 26 established a numerical model of material on a heterogeneous fiber matrix to study the effect of the processing parameters on the substrate temperature rise, and the results show that the adjacent pulse energy can greatly increase the temperature of the substrate. Viboon et al 27 proposed a new novel technique the laser machining process was performed in an ice laser and investigated the heat transfer and the ablation mechanism of laser processing in the ice layer by the FEM method.…”

“…The finite element analysis (FEA) method is an effective way to investigate the HAZ, the heat transfer, and the machining mechanism 24,25 . Yang et al 26 established a numerical model of material on a heterogeneous fiber matrix to study the effect of the processing parameters on the substrate temperature rise, and the results show that the adjacent pulse energy can greatly increase the temperature of the substrate.…”

Improved interfacial bonding strength of silicone rubber/carbon fiber modified by dopamine

“…However, the above-mentioned method requires a high-cost instruments and experimental environment, and the treatment process is complicated, which will damage the CF to a certain extent and reduce its mechanical properties. [26,27] To avoid these problems, a "green" and efficient method has been found, based on biomimicry, to improve the surface activity of CF using the adhesion function of polydopamine (PDA). [28,29] Oxidative self-polymerization of dopamine (DA) in an alkaline buffer to form polydopamine, [30,31] which adsorbs onto the surface of objects.…”