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Numerical and experimental investigation of orthogonal cutting of carbon fiber-reinforced polyetheretherketone (CF/PEEK)

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Abstract

Carbon fiber-reinforced thermoplastic composites have gained much attention due to their excellent mechanical properties, corrosion resistance, short curing process, and easy recyclability. However, the current research on the machining of composites is mainly focused on the thermoset composites, and the influence of the thermoplastic matrix on the machining performance of the composites is still unclear. In this paper, orthogonal cutting experiments of carbon fiber-reinforced polyetheretherketone (CF/PEEK) were carried out and a 3-D micro numerical cutting model with considering the strain-rate-dependent mechanical properties of PEEK was established as well. The cutting force, fiber failure and machining damages predicted by the proposed model agree well with the experimental results. Based on the experimental and numerical simulation approaches, the effects of fiber orientation angles (\(\theta\)) and depth of cut (\({a}_{c}\)) on the cutting mechanism, cutting force, and surface integrity of CF/PEEK were investigated in detail. The results indicate that fiber orientation is still the dominant factor in the CF/PEEK machining process; however, compared to the machinability of carbon fiber-reinforced thermoset composite, the certain ductility of PEEK matrix leads to continuous curly chip formation and differences in machined surface quality. Meanwhile, the machining damage formation mechanism was studied through a combination of experimental and simulation approaches.

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Data availability

The data that support the findings of this study are available from the corresponding author upon reasonable request.

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Funding

This work was supported by National Natural Science Foundation of China (Grant numbers: 51775373, 51705358 and 52075380), and Natural Science Foundation of Tianjin (Grant number: 19JCYBJC19000).

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Authors and Affiliations

  1. Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin, 300072, China

    Xuda Qin, Xiaozhong Wu, Hao Li, Shipeng Li & Shiguang Zhang

  2. School of Mechanical and Aerospace Engineering, Queens University, Belfast, BT5 9AH, UK

    Yan Jin

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  1. Xuda Qin
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  2. Xiaozhong Wu
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  3. Hao Li
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  4. Shipeng Li
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Contributions

Xuda Qin: investigation, experimental design, data analysis, writing and editing. Xiaozhong Wu: finite element model, numerical and experimental data analysis, writing and editing. Hao Li: investigation, preparation of experimental materials, review and editing. Shipeng Li: investigation, preparation of experimental materials, review and editing. Shiguang Zhang: review and editing. Yan Jin: reivew and editing.

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Correspondence to Hao Li.

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Appendix A. The material parameters used in the FE model and experiment

Appendix A. The material parameters used in the FE model and experiment

Table 2 Material properties utilized in the numerical model [4, 5, 8, 15, 17, 26, 29, 36, 37]
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Table 3 Material properties of CF/PEEK
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Qin, X., Wu, X., Li, H. et al. Numerical and experimental investigation of orthogonal cutting of carbon fiber-reinforced polyetheretherketone (CF/PEEK). Int J Adv Manuf Technol 119, 1003–1017 (2022). https://doi.org/10.1007/s00170-021-08317-3

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