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Force coefficient prediction for drilling of UD-CFRP based on FEM simulation of orthogonal cutting

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Abstract

This paper presents a mechanistic model for prediction of fluctuating thrust force and torque during drilling of unidirectional carbon fiber–reinforced polymer (UD-CFRP). A micro-scale model consisting of fiber, matrix, and fiber-matrix interface is proposed to simulate the orthogonal cutting behavior for the entire range of fiber orientation. Based on the FE model, a detailed energy analysis is conducted to quantify the various energy-absorbing mechanisms. The relationship between the percentage of each mechanism and factors such as depth of cut, tool rake angle, and fiber orientation is revealed. Afterwards, force coefficients related to these factors are obtained based on the orthogonal cutting database and used to calculate the instantaneous thrust forces and torque generated on the cutting lips, which are divided into a continuous set of infinitesimal elements conducting orthogonal cutting. Orthogonal cutting and drilling experiments with various machining parameters have been performed to validate the proposed FE and mechanistic models. Good correlation between the experimental and predicted results is found and thus the model is capable of predicting the fluctuation of thrust forces and torque for the whole drilling process.

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Acknowledgments

A great thanks goes to Mr. Jian Gao and Dr. Yusuf Altintas from the University of British Columbia for their support in this work. The authors would like to acknowledge the editors and the anonymous referees for their insightful comments.

Funding

This research is supported by the National Natural Science Foundation of China under Grant No. 51705426, the National Key Research and Development Program of China under Grant No. 2018YFB1703102, and the National Science Fund for Distinguished Young Scholars under Grant No. 2018JC-009.

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  1. School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, Shaanxi, China

    Xiaoye Yan, Kaifu Zhang, Hui Cheng, Bin Luo & Guoyi Hou

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  1. Xiaoye Yan
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Correspondence to Kaifu Zhang.

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Yan, X., Zhang, K., Cheng, H. et al. Force coefficient prediction for drilling of UD-CFRP based on FEM simulation of orthogonal cutting. Int J Adv Manuf Technol 104, 3695–3716 (2019). https://doi.org/10.1007/s00170-019-04048-8

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