A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates
Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cu...
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| Format: | Article |
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MDPI AG
2021-05-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/11/11/4743 |
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| author | Fernando Cepero-Mejias Nicolas Duboust Vaibhav A. Phadnis Kevin Kerrigan Jose L. Curiel-Sosa |
| author_facet | Fernando Cepero-Mejias Nicolas Duboust Vaibhav A. Phadnis Kevin Kerrigan Jose L. Curiel-Sosa |
| author_sort | Fernando Cepero-Mejias |
| collection | DOAJ |
| description | Nowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cutting tool significantly hinder the modelling of these types of processes. For these reasons, the numerical study of common machining operations, especially in composite machining, is still minimal. This paper presents a novel approach comprising a mixed multidirectional composite damage mode with composite edge trimming operation. An ingenious finite element framework which infer the cutting edge tool wear assessing the incremental change of the machining forces is developed. This information is essential to replace tool inserts before the tool wear could cause severe damage in the machined parts. Two unidirectional carbon fibre specimens with fibre orientations of 45<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mo>°</mo></msup></semantics></math></inline-formula> and 90<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mo>°</mo></msup></semantics></math></inline-formula> manufactured by pre-preg layup and cured in an autoclave were tested. Excellent machining force predictions were obtained with errors below 10% from the experimental trials. A consistent 2D FE composite damage model previously performed in composite machining was implemented to mimic the material failure during the machining process. The simulation of the spring back effect was shown to notably increase the accuracy of the numerical predictions in comparison to similar investigations. Global cutting forces simulated were analysed together with the cutting tool tooth forces to extract interesting conclusions regarding the forces received by the spindle axis and the cutting tool tooth, respectively. In general terms, vertical and normal forces steadily increase with tool wear, while tangential to the cutting tool, tooth and horizontal machining forces do not undergo a notable variation. |
| first_indexed | 2024-03-10T11:10:03Z |
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| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-10T11:10:03Z |
| publishDate | 2021-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-2789a3cb68be4758a3c15b4d2e390d852023-11-21T20:48:56ZengMDPI AGApplied Sciences2076-34172021-05-011111474310.3390/app11114743A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP LaminatesFernando Cepero-Mejias0Nicolas Duboust1Vaibhav A. Phadnis2Kevin Kerrigan3Jose L. Curiel-Sosa4Department of Mechanical Engineering, The University of Sheffield, Sir Frederick Mappin Building, Mappin Street, Sheffield S1 3JD, UKAdvanced Manufacturing Research Centre with Boeing, University of Sheffield, Advanced Manufacturing Park, Wallis Way, Catcliff, Rotherham S60 5TZ, UK3M UK Plc, Bracknell RG12 8HT, UKAdvanced Manufacturing Research Centre with Boeing, University of Sheffield, Advanced Manufacturing Park, Wallis Way, Catcliff, Rotherham S60 5TZ, UKDepartment of Mechanical Engineering, The University of Sheffield, Sir Frederick Mappin Building, Mappin Street, Sheffield S1 3JD, UKNowadays, the development of robust finite element models is vital to research cost-effectively the optimal cutting parameters of a composite machining process. However, various factors, such as the high computational cost or the complicated nature of the interaction between the workpiece and the cutting tool significantly hinder the modelling of these types of processes. For these reasons, the numerical study of common machining operations, especially in composite machining, is still minimal. This paper presents a novel approach comprising a mixed multidirectional composite damage mode with composite edge trimming operation. An ingenious finite element framework which infer the cutting edge tool wear assessing the incremental change of the machining forces is developed. This information is essential to replace tool inserts before the tool wear could cause severe damage in the machined parts. Two unidirectional carbon fibre specimens with fibre orientations of 45<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mo>°</mo></msup></semantics></math></inline-formula> and 90<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mrow></mrow><mo>°</mo></msup></semantics></math></inline-formula> manufactured by pre-preg layup and cured in an autoclave were tested. Excellent machining force predictions were obtained with errors below 10% from the experimental trials. A consistent 2D FE composite damage model previously performed in composite machining was implemented to mimic the material failure during the machining process. The simulation of the spring back effect was shown to notably increase the accuracy of the numerical predictions in comparison to similar investigations. Global cutting forces simulated were analysed together with the cutting tool tooth forces to extract interesting conclusions regarding the forces received by the spindle axis and the cutting tool tooth, respectively. In general terms, vertical and normal forces steadily increase with tool wear, while tangential to the cutting tool, tooth and horizontal machining forces do not undergo a notable variation.https://www.mdpi.com/2076-3417/11/11/4743machiningmachining forcesfinite elementmodellingedge trimmingCFRP |
| spellingShingle | Fernando Cepero-Mejias Nicolas Duboust Vaibhav A. Phadnis Kevin Kerrigan Jose L. Curiel-Sosa A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates Applied Sciences machining machining forces finite element modelling edge trimming CFRP |
| title | A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates |
| title_full | A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates |
| title_fullStr | A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates |
| title_full_unstemmed | A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates |
| title_short | A Novel Finite Element Method Approach in the Modelling of Edge Trimming of CFRP Laminates |
| title_sort | novel finite element method approach in the modelling of edge trimming of cfrp laminates |
| topic | machining machining forces finite element modelling edge trimming CFRP |
| url | https://www.mdpi.com/2076-3417/11/11/4743 |
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