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Effect mechanism of plain-woven structure of carbon fiber on CFRP cutting

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Abstract

Carbon fiber–reinforced plastic (CFRP) is increasingly employed as structural components for aircrafts in aerospace. The plain-woven CFRP is more commonly used than the UD-CFRP. The machining-induced damages are easy to occur. The influence of the plain-woven structure on the cutting mechanism and the defects occurrence mechanism are seldom studied in detail. In this paper, the three-dimensional FEM model of plain-woven CFRP is established. The occurrence and propagation of the delamination are investigated. The results indicate that the stress concentrations are easy to occur at the junction of warp and fill bundles near the cutting position. The plain-woven structure can block the transfer of stress and the crack propagation. When θ = 90°, the damages of the fill fibers and the crack of the interface are easy to occur. When θ = 45°, the step-like fracture is formed in both of the warp and the fill bundles, especially in the fill bundles. Under the same cutting conditions, the exit delamination of the plain-woven CFRP is obviously less than that of the UD-CFRP. The delamination greatly increases with the increase of the feed speed. The delamination decreases with the increase of the cutting speed. The delamination is closely related to the instantaneous cutting position of the cutter.

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Data availability

All data generated or analyzed during this study are included in this published article.

Abbreviations

oxy :

Coordinate system of bundle

P 1 :

Amplitude of the bending curve in y direction (P1 = a/2)

a :

Hickness of the bundle cross-section center

b :

Distance between two adjacent warp bundles

P 3 :

Offset distance of the bending curve in y direction

d :

Thickness of cross-section edge

E f :

Young’s elastic modulus of the fiber

E m :

Young’s elastic modulus of the matrix

c f :

Fiber volume fraction

c m :

Matrix volume fraction

G f :

Fiber shear modulus

G m :

Matrix shear modulus

ν f :

Fiber Poisson’s ratio

ν m :

Matrix Poisson’s ratio

E 1 :

Equivalent elastic modulus in 1-direction (viz., the fiber axial direction)

E 2 :

Equivalent elastic modulus in 2-direction (viz., vertical the fiber axial direction)

G 12 :

In-plane shear modulus

ν 12 :

Equivalent Poisson’s ratio for the deformation in 2-direction causing by the stress in 1-direction

ν 21 :

Equivalent Poisson’s ratio for the deformation in 1-direction causing by the stress in 2-direction

θ :

Warp fiber orientation

X t :

Ultimate tensile strength

X c :

Ultimate compressive strength

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Funding

This work was financially supported by the National Science Foundation of China (No. 52175400, No. 51805164, No. 52075127), Natural Science Foundation of Hunan Province (No. 2021JJ30263), and Natural Science Foundation of Jiangsu Province (No.BK20201474).

Author information

Authors and Affiliations

  1. School of Mechatronics Engineering, Harbin Institute of Technology, Heilongjiang Harbin, 150001, China

    Guojun Dong

  2. Intelligent Manufacturing Institute of HNUST, Hunan University of Science and Technology, Hunan Xiangtan, 411201, China

    Fei Su, Chunjie Li & Bing Chen

  3. Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-To-Cut Material, Hunan University of Science and Technology, Hunan Xiangtan, 411201, China

    Fei Su, Chunjie Li & Bing Chen

  4. School of Mechanical Engineering, Yancheng Institute of Technology, Jiangsu Yancheng, 224051, China

    Lei Zheng

Authors
  1. Guojun Dong
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  2. Fei Su
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  3. Chunjie Li
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  4. Lei Zheng
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  5. Bing Chen
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Contributions

Su Fei: conceptualization, formal analysis, resources, writing—review and editing, supervision, project administration, funding acquisition. Guojun Dong: modeling analysis, test operation, writing—review and editing (Sect. 4). Chunjie Li: methodology, validation, investigation, data curation, writing original draft. Zhen Lei: data curation, writing-review and editing (Sect. 2.3). Bing Chen: test operation, Matlab programming.

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Correspondence to Fei Su.

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Dong, G., Su, F., Li, C. et al. Effect mechanism of plain-woven structure of carbon fiber on CFRP cutting. Int J Adv Manuf Technol 119, 3223–3234 (2022). https://doi.org/10.1007/s00170-021-08470-9

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  • DOI: https://doi.org/10.1007/s00170-021-08470-9

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