Chip formation and surface damage in orthogonal cutting of plain-woven CFRP
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摘要: 平纹编织结构碳纤维增强树脂基复合材料(Plain-woven carbon fiber-reinforced plastic,PW-CFRP)展现出高损伤容限特性,在航空航天领域应用广泛,但PW-CFRP是一种多尺度复合材料,传统的微、宏观尺度并不能较好地去研究其切削机制,因此本文采用介观层面切削仿真手段对其切屑形成机制进行研究。本文根据PW-CFRP的几何结构特点建立介观尺度的三维正交切削仿真模型,同时开展正交切削试验,对仿真模型进行验证;研究了不同纤维编织方向PW-CFRP在切削加工中的材料去除机制。研究结果表明:在相同工艺参数条件下,切削力和表面损伤的仿真与实验结果最大相对误差不超过15%,仿真模型的可靠性得以验证;其中各纤维方向纤维束区域的最大损伤深度依次为0°<45°<90°<135°;经纬编织的平纹编织结构对切削加工损伤起到一定的抑制作用,相邻纤维束间的支撑约束作用阻碍了损伤扩展,其最大加工损伤深度不会超出纤维束截面最大宽度;纤维附近树脂层厚度是加工损伤形成的重要因素,树脂富集区域对纤维的支撑作用较好,可以有效抑制损伤,树脂薄弱区域对纤维支撑较弱,损伤容易扩展至此处,使材料表面损伤呈弧形分布。
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关键词:
- 平纹编织结构CFRP /
- ABAQUS /
- 正交切削 /
- 纤维方向 /
- 材料去除机制
Abstract: Plain-woven carbon fiber-reinforced plastic (PW-CFRP) shows high damage tolerance characteristics and is widely used in the aerospace field. However, PW-CFRP is a multi-scale composite material, and the traditional micro and macro scales cannot study its cutting mechanism well. Therefore, this paper uses mesoscopic cutting simulation methods to study its chip formation mechanism. In this paper, a mesoscopic three-dimensional orthogonal cutting simulation model was established according to the geometric structure characteristics of PW-CFRP, and the orthogonal cutting experiment was carried out to verify the simulation model. The material removal mechanism of PW-CFRP with different fiber braiding directions in cutting process was studied. The results show that the maximum relative error between the simulation and experimental results of cutting force and surface damage is less than 15% under the same process parameters, and the reliability of the simulation model is verified. The maximum damage depth of fiber bundles in each fiber orientation is 0°<45°<90°<135°. The plain-woven structure of warp and fill weaving has inhibitory effect on the machining damage. The support constraint between adjacent fiber bundles hinders the damage expansion, and its maximum processing damage depth will not exceed the maximum width of the fiber bundle section. The thickness of the matrix layer near the fiber is an important factor in the formation of processing damage. The resin-rich area has a good supporting effect on the fiber and can effectively suppress the damage. The resin-starved area has weak support for the fiber, and the damage is easy to expand here, making the surface damage of the material arc-shaped distribution.-
Key words:
- plain woven CFRP /
- ABAQUS /
- orthogonal cutting /
- fiber orientation /
- material removal mechanism
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图 1 平纹编织结构碳纤维增强树脂基复合材料(PW-CFRP)截面实物图与结构示意图
Figure 1. Physical and structural diagram of plain-woven carbon fiber-reinforced plastic (PW-CFRP)
A0—Fiber bundle width; H0—Maximum thickness of fiber bundle interface; h0—Thickness of resin-starved area; hm—Thickness of resin-rich area; φ—Fibre fluctuation angle
图 4 树脂基体材料本构
Figure 4. Constitutive model of matrix material
σ0—Resin yield stress; σy0—Resin yield strength; E0—Initial elastic modulus of resin; Ed—Elastic modulus of resin after degradation; dm—Damage state variable; σ—Equivalent plastic stress; ε—Equivalent plastic strain; $\overline \sigma $—Mean yield stress; E—Modulus of elasticity; ${\overline \varepsilon _0} $—Initial plastic strain; ${\overline \varepsilon _{\rm{f}}} $—Maximum plastic strain
表 1 仿真模型几何尺寸参数
Table 1. Geometric dimension parameters of simulation model
A0/mm H0/mm Vf h0/mm 1.8 0.15 55% 0.05 Phase composition Material parameter Value Fiber bundle X1t f/MPa 4900 X1c f/MPa 4500 X2t f/MPa 400 X2c f/MPa 700 X3t f/MPa 400 X3c f/MPa 700 S12 f/MPa 100 S13 f/MPa 100 S23 f/MPa 58 Matrix ρm/(kg·m−3) 980 Em/MPa 4000 νm 0.4 σy0 m /MPa 270 Interface properties Nmax/MPa 60 Smax/MPa 90 Tmax/MPa 90 $ {G}_{\mathrm{n}}^{\mathrm{c}} $/(N·m−1) 0.2 $ {G}_{\mathrm{s}}^{\mathrm{c}} $/(N·m−1) 1.0 $ {G}_{\mathrm{t}}^{\mathrm{c}} $/(N·m−1) 1.0 Notes:X1t f—Tensile strength of fiber bundles in 1 direction; X2t f—Tensile strength of fiber bundles in 2 direction; X3t f—Tensile strength of fiber bundles in 3 direction; X1c f—Compressive strength of fiber bundles in the 1 direction; X2c f—Compressive strength of fiber bundles in 2 direction; X3c f—Compressive strength of fiber bundles in 3 direction; S12 f—Shear strength of fiber bundles in 1-2 plane; S23 f—Shear strength of fiber bundles in 2-3 plane; S13 f—Shear strength of fiber bundles in 1-3 plane. ρm—Matrix density; Em—Young's modulus of matrix; νm—Poisson's ratio of matrix; σy0 m—Yield strength of the matrix; Nmax—Normal stress intensity of interface; Smax—First tangential stress intensity of interface; Tmax—Second tangential stress intensity of interface; $ {G}_{\mathrm{n}}^{\mathrm{c}} $—Normal critical fracture energy of interface; $ {G}_{\mathrm{s}}^{\mathrm{c}} $—First tangential critical fracture energy of interface; $ {G}_{\mathrm{t}}^{\mathrm{c}} $—Second tangential critical fracture energy of interface. 表 3 正交切削试验参数
Table 3. Process parameters of orthogonal cutting experiment
v/(mm·min−1) ap/mm γ/(°) α/(°) 2 000 0.1 15 12 Notes: v—Cutting speed; ap—Cutting depth. -
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