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Investigation on cutting damage mechanism of carbon fiber reinforced polymer based on macro/microscopic simulation

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Abstract

Carbon fiber reinforced polymer (CFRP) is widely used in the aerospace field due to its excellent physical and mechanical properties such as high specific strength, high specific modulus, and good corrosion resistance. However, it is prone to bring burrs, tears, matrix, and fiber debonding during the cutting process due to its non-homogeneity and anisotropy, which seriously affects the service life of the material. To explore the damage failure mechanism of the CFRP cutting process, 2D and 3D finite element simulation models were established based on Abaqus in this paper. Furthermore, the influence law of fiber direction on cutting damage failure and chip forming was analyzed from micro and macro levels. Finally, the effectiveness of the simulation model was verified by experiments. The results show that the cutting surface of CFRP with a 45° fiber angle is serrated, and the local failure is not obvious; the main defect of CFRP with 90° fiber angle cutting is a matrix and fiber debonding, and some fibers will be crushed and off. Serious degumming phenomenon occurred in the cutting process of CFRP with 135° fiber angle, and the bending and fracture of fiber also occur below the cutting depth. It is noteworthy that the stress distribution diverges along the fiber direction.

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The raw/processed data required to reproduce these findings cannot be shared at this time as the data also forms part of an ongoing study.

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Funding

This work was supported by Natural and Science Foundation of China (52205455), Natural and Science Foundation of Fujian Province (2021J01560), and Education and scientific research foundation for young teachers in Fujian Province (JAT190006).

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Authors and Affiliations

  1. School of Mechanical Engineering and Automation, Fuzhou University, Fuzhou, Fujian, People’s Republic of China

    Zhaoju Zhu, Rongqing Kang, Jianwei Huang, Yunqi Zhu & Xinhui Sun

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  1. Zhaoju Zhu
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  2. Rongqing Kang
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  3. Jianwei Huang
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  4. Yunqi Zhu
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  5. Xinhui Sun
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Contributions

Zhaoju Zhu worked on conceptualization, methodology, formal analysis, and preparation of the original draft with input from all authors. Rongqing Kang and Jianwei Huang developed the computational modal, design optimization, and conducted the experiments. Yunqi Zhu and Xinghui Sun worked on data collection, processing, and segmentation. Zhaoju Zhu supervised the project.

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Correspondence to Zhaoju Zhu.

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Zhu, Z., Kang, R., Huang, J. et al. Investigation on cutting damage mechanism of carbon fiber reinforced polymer based on macro/microscopic simulation. Int J Adv Manuf Technol 127, 3585–3597 (2023). https://doi.org/10.1007/s00170-023-11739-w

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  • DOI: https://doi.org/10.1007/s00170-023-11739-w

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