3D finite element modeling of chip formation and induced damage in machining Fiber reinforced composite

摘要

With the increasing demand for composite materials in many applications such as aerospace and automotive, their behavior needs to be thoroughly investigated, especially during and after failure. In the present work a three-dimensional (3D) finite element (FE) model is developed to study the machining of unidirectional (UD) carbon fiber reinforced polymer composite (CFRP). Chip formation process and ply damage modes such as matrix cracking, fiber matrix shear, and fiber failure are modeled by degrading the material properties. The 3D Hashin failure criteria are used and implemented in the commercial finite element program Abaqus, using a VUMAT subroutine. The objective of this study is to understand the 3D chip formation process and to analyze the cutting induced damage from initiation stage until complete chip formation. The effect of fiber orientation on cutting forces is investigated. The numerical results have been compared with experimental results taken from the literature and showing a good agreemen t