Hybrid Finite Element–Smoothed Particle Hydrodynamics Modelling for Optimizing Cutting Parameters in CFRP Composites
Carbon-fibre-reinforced plastic (CFRP) is increasingly being used in various applications including aerospace, automotive, wind energy, sports, and robotics, which makes the precision modelling of its machining operations a critical research area. However, the classic finite element modelling (FEM)...
| Main Authors: | , , , , , , , |
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-06-01
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| Series: | Polymers |
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| Online Access: | https://www.mdpi.com/2073-4360/15/13/2789 |
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| author | Alessandro Abena Sabbah Ataya Hany Hassanin Mahmoud Ahmed El-Sayed Mahmoud Ahmadein Naser A. Alsaleh Mohamed M. Z. Ahmed Khamis Essa |
| author_facet | Alessandro Abena Sabbah Ataya Hany Hassanin Mahmoud Ahmed El-Sayed Mahmoud Ahmadein Naser A. Alsaleh Mohamed M. Z. Ahmed Khamis Essa |
| author_sort | Alessandro Abena |
| collection | DOAJ |
| description | Carbon-fibre-reinforced plastic (CFRP) is increasingly being used in various applications including aerospace, automotive, wind energy, sports, and robotics, which makes the precision modelling of its machining operations a critical research area. However, the classic finite element modelling (FEM) approach has limitations in capturing the complexity of machining, particularly with regard to the interaction between the fibre–matrix interface and the cutting edge. To overcome this limitation, a hybrid approach that integrates smoothed particle hydrodynamics (SPHs) with FEM was developed and tested in this study. The hybrid FEM-SPH approach was compared with the classic FEM approach and validated with experimental measurements that took into account the cutting tool’s round edge. The results showed that the hybrid FEM-SPH approach outperformed the classic FEM approach in predicting the thrust force and bounce back of CFRP machining due to the integrated cohesive model and the element conversion after failure in the developed approach. The accurate representation of the fibre–matrix interface in the FEM-SPH approach resulted in predicting precise chip formation in terms of direction and morphology. Nonetheless, the computing time of the FEM-SPH approach is higher than the classic FEM. The developed hybrid FEM-SPH model is promising for improving the accuracy of simulation in machining processes, combining the benefits of both techniques. |
| first_indexed | 2024-03-11T01:31:00Z |
| format | Article |
| id | doaj.art-114a833fa57647ad9058d6f533515f29 |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-11T01:31:00Z |
| publishDate | 2023-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-114a833fa57647ad9058d6f533515f292023-11-18T17:20:06ZengMDPI AGPolymers2073-43602023-06-011513278910.3390/polym15132789Hybrid Finite Element–Smoothed Particle Hydrodynamics Modelling for Optimizing Cutting Parameters in CFRP CompositesAlessandro Abena0Sabbah Ataya1Hany Hassanin2Mahmoud Ahmed El-Sayed3Mahmoud Ahmadein4Naser A. Alsaleh5Mohamed M. Z. Ahmed6Khamis Essa7School of Engineering, University of Birmingham, Birmingham B152TT, UKDepartment of Mechanical Engineering, Imam Mohammad Ibn Saud Islamic University (IMSIU), Riyadh 11432, Saudi ArabiaSchool of Engineering, Technology, and Design, Canterbury Christ Church University, Canterbury CT11QU, UKDepartment of Industrial and Management Engineering, Arab Academy for Science, Technology and Maritime Transport, Alexandria 21599, EgyptDepartment of Production Engineering and Mechanical Design, Tanta University, Tanta 31512, EgyptDepartment of Mechanical Engineering, Imam Mohammad Ibn Saud Islamic University (IMSIU), Riyadh 11432, Saudi ArabiaMechanical Engineering Department, College of Engineering at Al Kharj, Prince Sattam Bin Abdulaziz University, Al Kharj 16273, Saudi ArabiaSchool of Engineering, University of Birmingham, Birmingham B152TT, UKCarbon-fibre-reinforced plastic (CFRP) is increasingly being used in various applications including aerospace, automotive, wind energy, sports, and robotics, which makes the precision modelling of its machining operations a critical research area. However, the classic finite element modelling (FEM) approach has limitations in capturing the complexity of machining, particularly with regard to the interaction between the fibre–matrix interface and the cutting edge. To overcome this limitation, a hybrid approach that integrates smoothed particle hydrodynamics (SPHs) with FEM was developed and tested in this study. The hybrid FEM-SPH approach was compared with the classic FEM approach and validated with experimental measurements that took into account the cutting tool’s round edge. The results showed that the hybrid FEM-SPH approach outperformed the classic FEM approach in predicting the thrust force and bounce back of CFRP machining due to the integrated cohesive model and the element conversion after failure in the developed approach. The accurate representation of the fibre–matrix interface in the FEM-SPH approach resulted in predicting precise chip formation in terms of direction and morphology. Nonetheless, the computing time of the FEM-SPH approach is higher than the classic FEM. The developed hybrid FEM-SPH model is promising for improving the accuracy of simulation in machining processes, combining the benefits of both techniques.https://www.mdpi.com/2073-4360/15/13/2789finite element modellingsmoothed particle hydrodynamicsorthogonal cuttingchip formation |
| spellingShingle | Alessandro Abena Sabbah Ataya Hany Hassanin Mahmoud Ahmed El-Sayed Mahmoud Ahmadein Naser A. Alsaleh Mohamed M. Z. Ahmed Khamis Essa Hybrid Finite Element–Smoothed Particle Hydrodynamics Modelling for Optimizing Cutting Parameters in CFRP Composites Polymers finite element modelling smoothed particle hydrodynamics orthogonal cutting chip formation |
| title | Hybrid Finite Element–Smoothed Particle Hydrodynamics Modelling for Optimizing Cutting Parameters in CFRP Composites |
| title_full | Hybrid Finite Element–Smoothed Particle Hydrodynamics Modelling for Optimizing Cutting Parameters in CFRP Composites |
| title_fullStr | Hybrid Finite Element–Smoothed Particle Hydrodynamics Modelling for Optimizing Cutting Parameters in CFRP Composites |
| title_full_unstemmed | Hybrid Finite Element–Smoothed Particle Hydrodynamics Modelling for Optimizing Cutting Parameters in CFRP Composites |
| title_short | Hybrid Finite Element–Smoothed Particle Hydrodynamics Modelling for Optimizing Cutting Parameters in CFRP Composites |
| title_sort | hybrid finite element smoothed particle hydrodynamics modelling for optimizing cutting parameters in cfrp composites |
| topic | finite element modelling smoothed particle hydrodynamics orthogonal cutting chip formation |
| url | https://www.mdpi.com/2073-4360/15/13/2789 |
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