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Study on the formation mechanism of cutting surface of carbon fiber-reinforced composites

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Abstract

Carbon fiber-reinforced plastic (CFRP) is used widely in aerospace. The cutting mechanism of CFRP is markedly different from that of metals due to anisotropic and non-homogeneous material structure. The cutting mechanisms are highly dependent on the fiber orientation. The quality of the machined surface can be affected by the fiber fracture models. In this paper, based on the elastic foundation beam theory and the Hertzian contact theory, the cutting mechanics are established. And the cutting model is simulated by the three-dimensional micro-scale numerical model. Then, the continuous varying cutting mechanism and the sub-damage are deeply studied in detail by combining the cutting mechanics model and the simulation model. The results indicate that the fiber orientation θ = 80° and θ = 150° is the transition critical point of the fracture form. When θ = 0°, the fiber failure mode is buckling dominated. When 0° < θ < 80° and 150° < θ < 180°, the fiber failure mode is dominated by contact fracture. When 80° < θ < 150°, the fiber failure mode is bending-dominated. The cutting mechanics model and finite element model can effectively reflect the evolution law of CFRP-machined surface.

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Data availability

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

Abbreviations

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)

E 3 :

Equivalent elastic modulus in 3 direction (viz., vertical the fiber axial direction)

E f :

Young’s elastic modulus of the fiber

E m :

Young’s elastic modulus of the matrix

ν f :

Fiber Poisson’s ratio

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 :

Fiber orientation

X t :

Ultimate tensile strength

X c :

Ultimate compressive strength

t0 n:

Represents the nominal stress normal-only mode

t0 s:

Represents the nominal stress first direction

t0 t:

Represents the nominal stress first direction

Gc n:

Represents the normal fracture energy

Gs c:

Represents the shear fracture energy

Gc t:

Represents the shear fracture energy

K nn :

Represents the rigidity normal direction

K ss :

Represents the rigidity shear direction

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Funding

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

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Authors and Affiliations

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

    Fei Su, Chunjie Li & Bing Chen

  2. 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

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

    Guojun Dong

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

    Lei Zheng

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

Fei Su: conceptualization, formal analysis, resources, writing-review and editing, supervision, project administration, and funding acquisition. Chunjie Li: methodology, validation, investigation, data curation, and writing original draft. Guojun Dong: modeling analysis, test operation, writing-review, and editing (Sects. 2.1 and 2.2). Lei Zhen: data curation, writing-review, and editing (Sect. 2.3). Bing Chen: test operation and Matlab programming.

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Correspondence to Fei Su or Guojun Dong.

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Authors have read the “Ethical Responsibilities of Authors” and “Compliance with Ethical Standards.” This study is an original paper which has neither previously nor simultaneously in whole or in part been submitted anywhere else. Results are presented clearly, honestly, and without fabrication, falsification, or inappropriate data manipulation. Complied fully with the COPE guidelines.

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Su, F., Li, C., Dong, G. et al. Study on the formation mechanism of cutting surface of carbon fiber-reinforced composites. Int J Adv Manuf Technol 121, 2049–2062 (2022). https://doi.org/10.1007/s00170-022-09478-5

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  • DOI: https://doi.org/10.1007/s00170-022-09478-5

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