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A 2.5D C/C composite cutting force prediction model based on brittle fracture mechanism

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Abstract

The C/C composite is a kind of composite with both functional and structural characteristics. It maintains the excellent physical and mechanical properties of the carbon matrix and fibers. Aiming at the low strength of C/C composite, the needle punching technology introduces fibers for reinforcement, which is called 2.5D C/C composite. In this paper, a 2.5D C/C composite cutting force prediction model based on brittle fracture mechanism is developed. Considering pores distribution, it proposes a material removal mechanism in the cutting process of 2.5D C/C composites. The edge indentation experiment is used to investigate the law of crack generation, expansion and path in the cutting process. It is also used to analyze the generation condition of chips with three types. Based on the law of energy conservation in the fracture mechanics theory, the brittle fracture mechanism is studied by introducing the instantaneous cut-in material proportion considering pores distribution. Furthermore, the relationship between the energy release rate of crack growth and the tangential force is established. The orthogonal cutting force model is derived according to the relationship. To validate the developed model and calibrate the correlation coefficients of the cutting force model, the orthogonal cutting experiment are performed. The pores distribution of the actual and simulated surface is analyzed by evaluating the probability density and the cumulative distribution function. Moreover, the average error for the cutting force prediction with the developed model is 8.62%.

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Funding

The present work is supported by the fund of National Natural Science Foundation of China (No. 51575453), the Science Center for Gas Turbine Project (No. P2021-A-IV-003–001) and the 111 project (Grant No. B13044).

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Authors and Affiliations

  1. Key Laboratory of High Performance Manufacturing for Aero Engine, Northwestern Polytechnical University, Xi’an, 710072, China

    Qianrui Zhang, Yue Tao, Ming Luo & Chenwei Shan

  2. Engineering Research Center of Advanced Manufacturing Technology for Aero Engine, Northwestern Polytechnical University, Xi’an, 710072, China

    Qianrui Zhang, Yue Tao, Ming Luo & Chenwei Shan

  3. School of Mechanical & Aerospace Engineering, Queens University Belfast, Belfast, BT9 5AH, UK

    Jia Ge

Authors
  1. Qianrui Zhang
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  2. Yue Tao
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  3. Ming Luo
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  4. Jia Ge
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  5. Chenwei Shan
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Contributions

QZ, ML and JG have generated the new research idea, designed methodology, done investigations and conducted experiments; QZ, YT and CS have conducted the experiments; ML and JG revised the manuscript, and all authors have actively participated in the revision and approved the manuscript.

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Correspondence to Ming Luo.

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Zhang, Q., Tao, Y., Luo, M. et al. A 2.5D C/C composite cutting force prediction model based on brittle fracture mechanism. Int J Adv Manuf Technol 123, 199–211 (2022). https://doi.org/10.1007/s00170-022-10088-4

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  • DOI: https://doi.org/10.1007/s00170-022-10088-4

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