Research on the mesoscopic cutting mechanism of CFRP based on three-dimensional multiphase finite element models

Abstract

As the single-phase macroscopic finite element method has some shortages in presenting the failure model and the chip formation of the fiber and matrix, several three-dimensional multiphase finite element models are established to simulate the orthogonal cutting behavior of carbon fiber reinforced plastic/polymer (CFRP) and acquire a more in-depth understanding of the.cutting mechanism of CFRP. First of all, the tool nose is scanned and measured, and the geometric models are set up according to the geometric information of the fiber, the matrix and the tool. Secondly, the constitutive relationship, involving elastic-plastic relationship, failure criterion and damage evolution, is described by VUMAT and various CFRP cutting simulations with different fiber orientations are conducted. The results of the simulations are verified by the orthogonal cutting experiments. The failure model, the chip formation and the sub-surface damage in different cutting situations are displayed visually. The relationship between fiber orientation and cutting forces is revealed by the outputted data of different cutting situations, and the finite element models are validated by the experimental results.