Simulation and experimental study of CFRP micro cutting considering voids defects
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摘要: 碳纤维增强树脂基复合材料(CFRP)在航空航天等领域应用广泛。在CFRP制造过程中难以避免会产生孔隙等缺陷，对后续的切削加工造成一定影响。在考虑了CFRP成型过程形成的孔隙缺陷基础上，运用有限元仿真模拟方法，从纤维-树脂-界面尺度建立了含孔隙缺陷的CFRP微观切削仿真模型，研究了不同孔隙率条件下不同纤维排布方向的CFRP微观切削行为，并通过实验验证了仿真模型的正确性。研究结果表明：孔隙的存在会增加刀具的“空切”现象，从而对CFRP切削过程的切削力、材料破坏及亚表面损伤、材料能量等产生影响。随孔隙率的增加，切削力呈下降趋势，孔隙边缘的纤维产生整体断裂的倾向增加；孔隙对0°、45°和135°纤维排布方向的CFRP切削加工的面下损伤影响不大，在纤维排布方向为90°条件下，孔隙率高于3vol%时对加工表面的面下损伤具有较大影响；在材料内部能量耗散方面，“顺切”(纤维方向角小于90°)时的总耗散能低于“逆切”，随孔隙率增加，总耗散能降低。Abstract: Carbon fiber-reinforced plastic (CFRP) composites have been widely used in aerospace and other most advanced fields. It is difficult to avoid voids and other defects in the manufacturing process of CFRP, which will have a certain impact on the subsequent machining. Based on the consideration of the voids defects in the process of CFRP forming, a CFRP micro cutting simulation model with void defects was established from the fiber-resin-interface scale by using the finite element simulation method. The micro cutting behavior of CFRP with different fiber orientations under different void content conditions was studied, and the correctness of the simulation model was verified by experiments. The results show that the existence of voids will increase the ‘virtual cutting’ phenomenon of the tool, which will have an impact on the cutting force, material damage, sub-surface damage and material energy in the cutting process of CFRP. The cutting force decreases with the increase of void content, and the tendency of fibers at the edge of voids to produce overall fracture will increase. The voids have little effect on the damage under the machined surface of CFRP with 0°, 45° and 135° fiber orientations. The void content higher than 3vol% has a great effect on the damage under the machined surface when the fiber orientation is 90°. In terms of energy dissipation inside the material, the total dissipated energy in ‘forward cut’ (fiber orientation angle less than 90°) is lower than ‘reverse cut’, furthermore, the total dissipated energy decreases with the increase of void content.
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Key words:
- CFRP /
- void /
- cutting /
- material damage /
- finite element simulation
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图 1 树脂本构模型[16]
Figure 1. Constitutive model of resin[16]
Em—Elastic modulus; dm—Stiffness degradation factor; σm—Stress of matrix; εm—Strain of matrix; $ {\sigma }_{\mathrm{m}}^{0} $—Starting point of plastic stage; $\sigma _{\rm{m}}^{{{{y}}_{\rm{0}}}} $—Yield stress at damage initiation point; $ {{\bar\varepsilon }}_{0}^{\mathrm{p}\mathrm{l}} $—Failure initiation strain; $ {{\bar\varepsilon }}_{\mathrm{m}}^{\mathrm{p}\mathrm{l}} $—Complete failure strain
图 2 含孔隙碳纤维增强树脂基复合材料 (CFRP)的微观切削建模
Figure 2. Micro cutting modeling of carbon fiber-reinforced plastic (CFRP) with voids
θ—Fiber orientation angle; α—Rake angle; γ—Clearance angle; Vp—Volumetric voids; U—Translational degrees of freedom; UR—Rotational degrees of freedom; RVE—Representative volume element; ap—Depth of cut
图 3 不同纤维角度θ和孔隙率下CFRP的切削力：(a) θ=0°；(b) θ=45°；(c) θ=90°；(d) θ=135°
Figure 3. Cutting force of CFRP under different fiber angles θ and void contents: (a) θ=0°; (b) θ=45°; (c) θ=90°; (d) θ=135°
Ave—Average cutting force; Max—Maximum cutting force
图 5 含不同孔隙率CFRP切削的材料断裂与损伤：(a) θ=0°；(b) θ=45°；(c) θ=90°；(d) θ=135°
Figure 5. Materials fracture and damage of CFRP cutting with different void contents: (a) θ=0°; (b) θ=45°; (c) θ=90°; (d) θ=135°
SHRCRT—Shear damage initiation criterion
图 6 不同孔隙含量的CFRP微观切削加工表面：(a) θ=0°；(b) θ=45°；(c) θ=90°；(d) θ=135°
Figure 6. Micro machined surface of CFRP with different void contents: (a) θ=0°; (b) θ=45°; (c) θ=90°; (d) θ=135°
图 7 不同孔隙含量的CFRP面下最大损伤深度
Figure 7. Maximum fracture depth under the surface of CFRP with different void contents
图 10 CFRP仿真与实验的最大切削力对比 (θ=90°)
Figure 10. Comparison of maximum cutting force of CFRP between simulation and experiment (θ=90°)
图 11 仿真与实验的CFRP切削加工表面形貌对比(无孔隙)
Figure 11. Comparison of cutting surface morphology of CFRP between simulation and experiment (0vol% void content)
图 12 CFRP切削加工表面的仿真与实验结果对比(孔隙率5vol%)
Figure 12. Comparison of simulation and experimental results of cutting surface of CFRP (5vol% voids content)
Material Parameter Value Carbon fiber Elastic modulus/GPa E1=231, E2=E3=15 Poisson’s ratio ${{v}_{12}} $=${{v}_{13}} $=0.2, ${{v}_{23}} $=0.25 Shear modulus/GPa G12=G13=15, G23=7 Tensile strength/GPa Xt=4.62, Yt=1.5 Compressive strength/GPa Xc=3.96, Yc=3.34 Resin Elastic modulus/GPa E=3.35 Poisson’s ratio ${{v}} $=0.35 Yield strength/MPa σy=120 Fracture energy/(N·mm−1) Gf=0.01 Interface Normal strength/MPa σmax=50 Shear strength/MPa τmax=75 Elastic stiffness/(N·mm−3) K=100000 Fracture energy/(N·mm−1) GI=0.002 
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表 2 有限元模型(FEM)切削工艺参数
Table 2. Cutting process parameters used in the finite element model (FEM)
Parameter Value Rake angle of tool/(°) 15 Clearance angle of tool/(°) 10 Edge radius of tool/μm 5 Depth of cutting/μm 35 Cutting speed/(mm·s−1) 300
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