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Micromechanical modeling of the machining behavior of natural fiber-reinforced polymer composites

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Abstract

This paper aims to develop a 2D finite element (FE) model at microscale for numerical simulation of the machining behavior of natural fiber-reinforced polymer (NFRP) composites. The main objective of this study is to reproduce the experimentally observed specific cutting behavior of natural fibers within the composite material. Flax fiber-reinforced polypropylene (PP) composites are modeled separately using an elasto-plastic behavior with a ductile damage criterion for flax fibers and PP matrix, while the microscopic interfaces are represented using the cohesive zone modeling (CZM). Numerical outputs are compared with experimental results for the FE model validation. Results show that the proposed FE model can reproduce the cutting force with a good precision for a large cutting speed range (12–80 m/min). The FE model shows also an efficiency and accuracy in predicting the cutting behavior of flax fibers by reproducing the fiber deformation, the fibers torn-off, and the fracture of the interfaces during machining. Moreover, the FE model can be an effective tool for analyzing the quality of the microscopic interfaces in the NFRP composites after machining.

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Funding

This study was financially supported by the urban community of Châlons-en-Champagne (Cités en Champagne - France).

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Authors and Affiliations

  1. MSMP Laboratory / EA7350, Arts et Métiers ParisTech, Rue Saint Dominique BP508, 51006, Châlons-en-Champagne, France

    Faissal Chegdani & Mohamed El Mansori

  2. Department of Industrial and Systems Engineering, Texas A&M University, 3131 TAMU, College Station, TX, 77843, USA

    Mohamed El Mansori & Satish T. S. Bukkapatnam

  3. Department of Mechanical Engineering, Texas A&M University, 3123 TAMU, College Station, TX, 77843, USA

    J. N. Reddy

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  1. Faissal Chegdani
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  2. Mohamed El Mansori
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  4. J. N. Reddy
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Correspondence to Faissal Chegdani.

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Chegdani, F., El Mansori, M., T. S. Bukkapatnam, S. et al. Micromechanical modeling of the machining behavior of natural fiber-reinforced polymer composites. Int J Adv Manuf Technol 105, 1549–1561 (2019). https://doi.org/10.1007/s00170-019-04271-3

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