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High-speed milling of CFRP composites: a progressive damage model of cutting force

  • Lifeng Zhang
  • Sheng Wang
  • Weilin Qiao
  • Zhan Li
  • Ning Wang
  • Jin Zhang
  • Tao WangEmail author
ORIGINAL ARTICLE
  • 68 Downloads

Abstract

Three-dimensional Hashin failure criterion and material stiffness degradation model were compiled by VUMAT subroutine. The Abaqus/Explicit solver was performed to establish progressive damage model of cutting force for CFRP high-speed milling, and high-speed milling experiments with different cutting parameters were carried out. Further, the impact mechanism of fiber cutting angle and cutting parameters on cutting force, stress, and material failure during milling was explored, and the material removal mechanism in high-speed milling of CFRP was revealed. The results show that the error between the experimental and simulated of cutting forces is less than 5%, which indicates that the progressive damage model is feasible. The fiber cutting angle has significant influence on cutting force and stress in cutting process, and the cutting direction has a significant influence on cutting force. In addition, cutting parameters play a critical role in cutting force, and the feed per tooth is the most significant factor affecting the cutting force. Simultaneously, the progressive damage model predicts that the shear failure of materials mainly concentrates in the cutting area and extends along the feed direction. Finally, the material removal mechanism of CFRP in high-speed milling was revealed combining cutting force experiment.

Keywords

Progressive damage model VUMAT subroutine High-speed milling Cutting force Material removal mechanism 

Notes

Funding information

This study received financial support from the Fundamental Research Funds for the Central Universities (No. 3122018C007), the National Natural Science Foundation of China (No. 51705518), the United National Science Funds and Civil Aviation Funds (No. U1633104), and the Open Funds of the State Key Lab of Digital Manufacturing Equipment and Technology (No. DMETKF2017018).

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Lifeng Zhang
    • 1
  • Sheng Wang
    • 1
  • Weilin Qiao
    • 1
  • Zhan Li
    • 1
  • Ning Wang
    • 1
  • Jin Zhang
    • 1
  • Tao Wang
    • 1
    Email author
  1. 1.College of Aeronautical EngineeringCivil Aviation University of ChinaTianjinChina

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