Drilling of carbon/carbon (C/C) composites is difficult to implement due to the materials’ high specific stiffness, brittleness, anisotropic, heterogeneous, and low thermal conductivity, resulting in tear, burr, poor surface quality, and rapid wear of cutters. Accurate and fast predictions of thrust forces and defects are important for C/C composites drilling process with high quality. In this paper, a finite element analysis method for drilling of 2.5D C/C composites is presented. An improved damage initiation model is proposed based on the Shokrieh-Lessard’s model and the Hashin’s failure criteria. Six different failure modes—X-direction fiber-matrix tension, X-direction fiber-matrix compression, Y-direction tension, Y-direction compression, normal tension, and normal compression—are considered and modeled separately. An improved 3D progressive failure model is developed to approximate real failure process of 2.5D C/C composites. For validation purpose, drilling tests have been performed and compared to the results of finite element analysis. The experimental result shows to be consistent well with the proposed model, yielding a relative difference of predicted thrust force from 8.07 to 13.86%. The model demonstrates its ability to predict thrust force, material failure process, and damage for different values of feedrate.
C/C composites Thrust force Drilling Finite element analysis Progressive failure model
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