Skip to main content
SpringerLink
Log in

Three-dimensional oblique cutting model for sub-surface damage analysis in CFRP/Ti stack composite machining

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Fiber-metal stack composite has been widely used in various aerospace industry due to its enhanced mechanical properties. It is still a challenge to machine such stack composite, for the disparate nature of each stacked constituent and the complex interaction between two constituents. The CFRP (Carbon Fiber Reinforced Plastic) is prone to get sub-surface damage in the chip formation process, which affects the mechanical property of the workpiece. Meanwhile, the sub-surface damage varies obviously under different interaction caused by different stacking sequences, and is also strongly influenced by fiber orientations and cutting parameters. However, only experimental researches on CFRP/Ti stack composite machining cannot reveal the cutting characters of the interface region with the impact of the titanium completely. In contrast, numerical simulation could offer sufficient capabilities to overcome the limitations of the experimentation. In this study, a new contribution is provided to study the sub-surface damage of the interface region versus the interaction of stacked constituents, fiber orientation and cutting parameters via numerical approach. To this aim, a three-dimensional oblique cutting model is developed to simulate the chip formation process of cutting two stacked constituents simultaneously. Different constitutive models and failure criteria are implemented to construct the entire machining behaviors of the stack composite. Simulation results, cutting forces and sub-surface damage depths obtained match well with the experimental ones, which could verify the correctness of the established model. The numerical results highlight the significant effects of fiber orientations, cutting parameters and stacking sequences on the sub-surface damage in the interface region. The variation trends of sub-surface damage are distinct in different fiber orientations and stacking sequences. The research provides a guidance on reduction of the sub-surface damage in machining stack composites.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Lazar MB, Xirouchakis P (2011) Experimental analysis of drilling fiber reinforced composites. Int J Mach Tools Manuf 51(12):937–946. https://doi.org/10.1016/j.ijmachtools.2011.08.009

    Article  Google Scholar 

  2. Montoya M, Calamaz M, Gehin D, Girot F (2013) Evaluation of the performance of the coated and uncoated carbide tools in drilling thick CFRP/aluminum alloy stacks. Int J Adv Manuf Technol 68(9–12):2111–2120. https://doi.org/10.1007/s00170-013-4817-0

    Article  Google Scholar 

  3. Cheng H, Zhang KF, Wang N, Luo B, Meng QX (2017) A novel six-state cutting force model for drilling-countersinking machining process of CFRP-al stacks. Int J Adv Manuf Technol 89(5–8):2063–2076. https://doi.org/10.1007/s00170-016-9236-6

    Article  Google Scholar 

  4. Xu J, Mansori ME (2016) Numerical modeling of stacked composite CFRP/Ti machining under different cutting sequence strategies. Int J Precis Eng Manuf 17(1):99–107. https://doi.org/10.1007/s12541-016-0013-0

    Article  Google Scholar 

  5. Liu DF, Tang YJ, Cong WL (2012) A review of mechanical drilling for composite laminates. Compos Struct 94(4):1265–1279. https://doi.org/10.1016/j.compstruct.2011.11.024

    Article  Google Scholar 

  6. Che D, Saxena I, Han P, Guo P, Ehmann KF (2014) Machining of carbon fiber reinforced plastics/polymers: a literature review. J Manuf Sci Eng-Trans ASME 136(3): 034001

  7. Xu J, Mansori ME (2016) Numerical studies of frictional response when cutting hybrid CFRP/Ti composite. Int J Adv Manuf Technol 87(1–4):657–675. https://doi.org/10.1007/s00170-016-8512-9

    Article  Google Scholar 

  8. Ezugwu EO, Wang ZM (1997) Titanium alloys and their machinability - a review. J Mater Process Technol 68(3):262–274. https://doi.org/10.1016/S0924-0136(96)00030-1

    Article  Google Scholar 

  9. Ezugwu EO, Bonney J, Silva RBD, Cakir O (2007) Surface integrity of finished turned Ti-6Al-4V alloy with PCD tools using conventional and high pressure coolant supplies. Int J Mach Tools Manuf 47(6):884–891. https://doi.org/10.1016/j.ijmachtools.2006.08.005

    Article  Google Scholar 

  10. Nurul AAKM, Ismail AF, Khairusshima MKN (2007) Effectiveness of uncoated WC-co and PCD inserts in end milling of titanium alloy-Ti-6Al-4V. J Mater Process Technol 192-193(5):147–158

    Google Scholar 

  11. Zitoune R, Krishnaraj V, Collombet F, Roux SL (2016) Experimental and numerical analysis on drilling of carbon fiber reinforced plastic and aluminum stacks. Compos Struct 146:148–158. https://doi.org/10.1016/j.compstruct.2016.02.084

    Article  Google Scholar 

  12. Henerichs M, Vob R, Tanaka H, Kuster F, Wegener K (2014). Analysis of material weakening in CFRP after a drilling operation. Procedia CIRP 24: 44–48

  13. Isbilir O, Ghassemieh E (2013) Comparative study of tool life and hole quality in drilling of CFRP/titanium stack using coated carbide drill. Mach Sci Technol 17(3):380–409. https://doi.org/10.1080/10910344.2013.806098

    Article  Google Scholar 

  14. Ramulu M, Branson T, Kim D (2001) A study on the drilling of composite and titanium stacks. Compos Struct 54(1): 67–77

  15. Park KH, Beal A, Kim D, Kwon P, Lantrip J (2011) Tool wear in drilling of composite/titanium stacks using carbide and polycrystalline diamond tools. Wear 271(11): 2826–2835

  16. Beal A, Kim D, Park KH, Kwon P (2014) A comparative study of carbide tools in drilling of CFRP and CFRP-Ti stacks. J Manf Sci Eng-Trans ASME 136(1):145–152

    Google Scholar 

  17. Wang B, Yin WD, Wang MH, Zheng YH, Li XP (2017) Edge chipping mechanism and failure time prediction on carbide cemented tool during drilling of CFRP/Ti stack. Int J Adv Manuf Technol 91(9–12):3015–3024. https://doi.org/10.1007/s00170-017-0017-7

    Article  Google Scholar 

  18. Arola D, Ramulu M (1997) Orthogonal cutting of fiber-reinforced composites: a finite element analysis. Int J Mech Sci 39(5):597–613. https://doi.org/10.1016/S0020-7403(96)00061-6

    Article  MATH  Google Scholar 

  19. Zenia S, Ayed LB, Nouari M, Delamézière A (2015) Numerical analysis of the interaction between the cutting forces, induced cutting damage, and machining parameters of CFRP composites. Int J Adv Manuf Technol 78(1–4):465–480. https://doi.org/10.1007/s00170-014-6600-2

    Article  Google Scholar 

  20. Soldani X, Santiuste C, Muñoz-Sánchez A, Miguélez H (2011) Influence of tool geometry and numerical parameters when modeling orthogonal cutting of LFRP composites. Compos Pt A-Appl Sci Manuf 42(9):1205–1216. https://doi.org/10.1016/j.compositesa.2011.04.023

    Article  Google Scholar 

  21. Santituse C, Miguélez H, Soldani X (2011) Out-of-plane failure mechanism in LFRP composite cutting. Compos Struct 93(11): 2706–2713

  22. Chen G, Ren C, Yang X, Jin X, Guo T (2011) Finite element simulation of high-speed machining of titanium alloy (Ti-6Al-4V) based on ductile failure model. Int J Adv Manuf Technol 56(9–12): 1027–1038

  23. Yaich M, Ayed Y, Bouaziz Z, Germain G (2017) Numerical analysis of constitutive coefficients effects on FE simulation of the 2D orthogonal cutting process: application to the Ti6Al4V. Int J Adv Manuf Technol 93(1–4):283–303. https://doi.org/10.1007/s00170-016-8934-4

    Article  Google Scholar 

  24. Qi Z, Zhang K, Cheng H, Liu S (2015) Numerical simulation for delamination during drilling of CFRP/al stacks. Mater Res Innova 19(sup6):S6): 98–S6):101. https://doi.org/10.1179/1432891715Z.0000000001457

    Article  Google Scholar 

  25. Xu J, Mansori ME (2016) Cutting modeling of hybrid CFRP/Ti composite with induced damage analysis. Mater 9(1):22. https://doi.org/10.3390/ma9010022

    Article  Google Scholar 

  26. Xu J, Mansori ME (2015) Cutting modeling using cohesive zone concept of titanium/CFRP composite stacks. Int J Precis Eng Manuf 16(10):2091–2100. https://doi.org/10.1007/s12541-015-0271-2

    Article  Google Scholar 

  27. Hashin Z, Rotem A (1973) A fatigue criterion for fiber-reinforced material. J Compos Mater 7(4):448–464. https://doi.org/10.1177/002199837300700404

    Article  Google Scholar 

  28. Hashin Z (1980) Failure criteria for unidirectional fiber composites. J Appl Mecha 47(2):329–334. https://doi.org/10.1115/1.3153664

    Article  Google Scholar 

  29. Phadnis VA, Makhdum F, Roy A, Silberschmidt VV (2013) Drilling in carbon/epoxy composites: experimental investigations and finite element implementation. Compos Pt A-Appl Sci Manuf 47(1):41–51. https://doi.org/10.1016/j.compositesa.2012.11.020

    Article  Google Scholar 

  30. Rao GVG, Mahajan P, Bhatnagar N (2008) Three-dimensional macro-mechanical finite element model for machining of unidirectional fiber reinforced polymer composites. Mater Sci Eng A 498(1–2): 142–149

  31. Gao C, Xiao J, Xu J, Ke Y (2016) Factor analysis of machining parameters of fiber-reinforced polymer composites based on finite element simulation with experimental investigation. Int J Adv Manuf Technol 83(5):1113–1125. https://doi.org/10.1007/s00170-015-7592-2

    Article  Google Scholar 

  32. Xi Y, Bermingham M, Wang G, Dargusch M (2013) Finite element modeling of cutting force and chip formation during thermally assisted machining of Ti6Al4V alloy. J Manuf Sci Eng-Trans ASME 135(6):061014. https://doi.org/10.1115/1.4025740

    Article  Google Scholar 

  33. Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21(1):31–48. https://doi.org/10.1016/0013-7944(85)90052-9

    Article  Google Scholar 

  34. Benzeggagh ML, Kenane M (1996) Measurement of mixed-mode delamination fracture toughness of unidirectional glass/epoxy composites with mixed-mode bending apparatus. Compos Sci Technol 56(4):439–449. https://doi.org/10.1016/0266-3538(96)00005-X

    Article  Google Scholar 

  35. Johnson GR, Cook WH (1983) A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures. In. Proc. of the 7th international symposium on ballistics. The Netherlands, 541-547

  36. Lapczyk I, Hurtado JA (2007) Progressive damage modeling in fiber-reinforced materials. Compos Pt A-Appl Sci Manuf 38(11):2333–2341. https://doi.org/10.1016/j.compositesa.2007.01.017

    Article  Google Scholar 

  37. Savani E, Pirondi A, Carta F, Nogueira AC, Hombergsmeier E (2012) Modeling delamination of Ti-CFRP interfaces. The 15th European Conference on Composite Materials, Venice, Italy, 24–28 (June)

Download references

Acknowledgments

This project is supported by National Natural Science Foundation of China-United with Liaoning Province (No. U1508207), National Natural Science Foundation of China (No. 51575082), National Key Basic Research Program of China (973 Program) (No. 2014CB046503), National Innovative Research Group (No. 51621064), and the Fundamental Research Funds for the Central Universities (No. DUT16TD01). The authors wish to thank the anonymous reviewers for their comments which led to improvements of this paper.

Author information

Authors and Affiliations

  1. Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education, School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    Zhen-yuan Jia, Chen Chen, Fu-ji Wang, Jian-wei Ma & Fan Yang

Authors
  1. Zhen-yuan Jia
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Chen Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Fu-ji Wang
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jian-wei Ma
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Fan Yang
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Jian-wei Ma.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Jia, Zy., Chen, C., Wang, Fj. et al. Three-dimensional oblique cutting model for sub-surface damage analysis in CFRP/Ti stack composite machining. Int J Adv Manuf Technol 96, 643–655 (2018). https://doi.org/10.1007/s00170-018-1626-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-018-1626-5

Keywords

Search

Navigation