Skip to main content
SpringerLink
Log in

Factor analysis of machining parameters of fiber-reinforced polymer composites based on finite element simulation with experimental investigation

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

A three-dimensional (3D) micromechanical finite element (FE) model of machining of fiber-reinforced polymer (FRP) composites was developed in the paper. The FE modeling considers the three phases of a composite, in which the interphase between the fiber and matrix can realize interfacial debonding to represent the failure of composites and allow heat transfer. The machined surface observations and surface roughness measurements of carbon fiber-reinforced polymer (CFRP) composites at different fiber orientations were done firstly, and then, the model predictions of the machining responses, such as cutting force, temperature, and surface roughness, at different fiber orientations were compared with various experimental data for model validation. It is indicated that the three-phase micromechanical model is capable of precisely predicting machining responses and describing the failure modes of fiber shearing or bending related with fiber orientations in the chip formation process. To investigate the complex coupling influences of multiple machining parameters on the key responses of CFRP composites, the single-factor analyses of each machining parameter were first carried out, and then, the multi-factorial analysis of multiple machining parameters was performed based on the orthogonal design of experiment and the analysis of variance (ANOVA) to quantitatively compare the influences of these key machining parameters on the cutting force and surface roughness. It was found that the fiber orientation angle, depth of cut, and cutting speed prove to be the important factors affecting the cutting force and surface roughness and that the coupling effects of these machining parameters all are relatively negligible in the machining of CFRP composites.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Salonitis K, Pandremenos J, Paralikas J, Chryssolouris G (2010) Multifunctional materials: engineering applications and processing challenges. Int J Adv Manuf Technol 49(5–8):803–826

    Article  Google Scholar 

  2. Golzar M, Poorzeinolabedin M (2010) Prototype fabrication of a composite automobile body based on integrated structure. Int J Adv Manuf Technol 49(9–12):1037–1045

    Article  Google Scholar 

  3. Haddad M, Zitoune R, Bougherar H, Castanié EF (2014) Study of trimming damages of CFRP structures in function of the machining processes and their impact on the mechanical behavior. Compos Part B 57:136–143

    Article  Google Scholar 

  4. Tsao CC (2008) Thrust force and delamination of core-saw drill during drilling of carbon fiber reinforced plastics (CFRP). Int J Adv Manuf Technol 37(1–2):23–28

    Article  Google Scholar 

  5. Shahrajabian H, Hadi M, Farahnakian M (2012) Experimental investigation of machining parameters on machinability of carbon fiber/epoxy composites. Int J Eng Innovative Technol 2(3):30–36

    Google Scholar 

  6. Farshbaf Zinati R, Razfar MR (2014) Experimental and modeling investigation of surface roughness in end-milling of polyamide 6/multi-walled carbon nano-tube composite. Int J Adv Manuf Technol 75(5–8):979–989

    Article  Google Scholar 

  7. Azmi AI, Lin RJT, Bhattacharyya D (2013) Machinability study of glass fibre-reinforced polymer composites during end milling. Int J Adv Manuf Technol 64(1–4):247–261

    Article  Google Scholar 

  8. Bagci E, Isik B (2006) Investigation of surface roughness in turning unidirectional GFRP composites by using RS methodology and ANN. Int J Adv Manuf Technol 31(1–2):10–17

    Article  Google Scholar 

  9. Abhishek K, Datta S, Mahapatra SS (2013) Response surface modeling on machining of CFRP composites: effect of process variables on surface roughness, MRR and tool-tip temperature. Int J Mech Eng Res 3(4):407–414

    Google Scholar 

  10. Palanikumar K (2008) Application of Taguchi and response surface methodologies for surface roughness in machining glass fiber reinforced plastics by PCD tooling. Int J Adv Manuf Technol 36(1–2):19–27

    Article  Google Scholar 

  11. Pecat O, Rentsch R, Brinksmeier E (2012) Influence of milling process parameters on the surface integrity of CFRP. Proc CIRP 1:466–470

    Article  Google Scholar 

  12. Chakladar ND, Pal SK, Mandal P (2012) Drilling of woven glass fiber-reinforced plastic-an experimental and finite element study. Int J Adv Manuf Technol 58(1–4):267–278

    Article  Google Scholar 

  13. Sorrentino L, Turchetta S (2014) Cutting forces in milling of carbon fibre reinforced plastics. Int J Manuf Eng 14:1–8

    Google Scholar 

  14. Rao GVG, Mahajan P, Bhatnagar N (2007) Micro-mechanical modeling of machining of FRP composites-cutting force analysis. Compos Sci Technol 67(3–4):579–593

    Article  Google Scholar 

  15. Mkaddem A, Demirci I, El Mansori M (2008) A micro–macro combined approach using FEM for modelling of machining of FRP composites: cutting forces analysis. Compos Sci Technol 68(15–16):3123–3127

    Article  Google Scholar 

  16. Yang SB, Xu JH, Fu YC, Wei WH (2012) Finite element modeling of machining of hydrogenated Ti-6Al-4V alloy. Int J Adv Manuf Technol 59(1–4):253–261

    Article  Google Scholar 

  17. Kalla D, Sheikh-Ahmad J, Twomey J (2010) Prediction of cutting forces in helical end milling fiber reinforced polymers. Int J Mach Tool Manuf 50(10):882–891

    Article  Google Scholar 

  18. Jahromi AS, Bahr B (2010) An analytical method for predicting cutting forces in orthogonal machining of unidirectional composites. Compos Sci Technol 70:2290–2297

    Article  Google Scholar 

  19. Zhang L (2009) Cutting composites: a discussion on mechanics modeling. J Mater Process Tech 209(1):4548–4552

    Article  Google Scholar 

  20. Lasri L, Nouari M, El Mansori M (2009) Modelling of chip separation in machining unidirectional FRP composites by stiffness degradation concept. Compos Sci Technol 69(5):684–692

    Article  Google Scholar 

  21. Calzada KA (2012) Modeling and interpretation of fiber orientation-based failure mechanisms in machining of carbon fiber-reinforced polymer composites. J Manuf Process 14(2):141–149

    Article  Google Scholar 

  22. Zitoune R, Collombet F, Lachaud F (2005) Experiment-calculation comparison of the cutting conditions representative of the long fiber composite drilling phase. Compos Sci Technol 65(3–4):455–466

    Article  Google Scholar 

  23. Santiuste C, Olmedo A, Soldani X, Miguélez H (2012) Delamination prediction in orthogonal machining of carbon long fiber-reinforced polymer composites. J Reinf Plast Compos 31(13):875–885

    Article  Google Scholar 

  24. Iliescu D, Gehin D, Iordanoff I, Girot F, Gutierrez M (2010) A discrete element method for the simulation of CFRP cutting. Compos Sci Technol 70(1):73–80

    Article  Google Scholar 

  25. Dandekar C, Shin Y (2008) Multiphase finite element modeling of machining unidirectional composites: prediction of debonding and fiber damage. J Manuf Sci Technol 130:1–12

    Google Scholar 

  26. Chippendale RD, Golosnoy IO, Lewin PL (2014) Numerical modelling of thermal decomposition processes and associated damage in carbon fibre composites. J Phys D Appl Phys 47:301–315

    Article  Google Scholar 

  27. Huang XG, Gillespie JW Jr, Bogetti T (2000) Process induced stress for woven fabric thick section composite structures. Compos Struct 49:303–312

    Article  Google Scholar 

  28. Wang Y, Hahn TH (2007) AFM characterization of the interfacial properties of carbon fiber reinforced polymer composites subjected to hygrothermal treatment. Compos Sci Technol 67(26):92–101

    Article  Google Scholar 

  29. Zhou P, Zhao FL (2010) The 3D evaluation method of cutting surface topography of carbon/carbon(C/C) composite. High Technol Lett 16(4):366–372

    Google Scholar 

  30. Khamel S, Ouelaa N, Bouacha K (2012) Analysis and prediction of tool wear, surface roughness and cutting forces in hard turning with CBN tool. J Mech Sci Technol 26(11):3605–3616

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. The State Key Laboratory of Fluid Power Transmission and Control, College of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China

    Chongyang Gao, Jianzhang Xiao & Yinglin Ke

  2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing, 210000, China

    Jiuhua Xu

Authors
  1. Chongyang Gao
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Jianzhang Xiao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Jiuhua Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yinglin Ke
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jiuhua Xu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gao, C., Xiao, J., Xu, J. et al. Factor analysis of machining parameters of fiber-reinforced polymer composites based on finite element simulation with experimental investigation. Int J Adv Manuf Technol 83, 1113–1125 (2016). https://doi.org/10.1007/s00170-015-7592-2

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7592-2

Keywords

Search

Navigation