平纹编织结构CFRP正交切削切屑形成及表面损伤

周强; 陈燕; 王晓宇; 张川川; 陈雪梅; 刘元吉; 陈清良; 勾江洋

平纹编织结构CFRP正交切削切屑形成及表面损伤

1.
南京航空航天大学　江苏省精密与微细制造技术重点实验室, 南京 210016
2.
成都飞机工业(集团)有限责任公司, 成都 610092)

基金项目: 国家自然科学基金 (51875284)

详细信息

通讯作者:
陈燕，博士，教授，博士生导师，研究方向为难加工材料的高效精密加工技术　E-mail: ninaych@nuaa.edu.cn

中图分类号: TB332;V257
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- HTML全文浏览量: 159
- 被引次数: 0
出版历程
- 收稿日期: 2022-10-11
- 修回日期: 2022-11-18
- 录用日期: 2022-12-02
- 网络出版日期: 2022-12-19

Chip formation and surface damage in orthogonal cutting of plain-woven CFRP

1.
Jiangsu Key Laboratory of Precision and Micro–Manufacturing Technology, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
2.
Chengdu Aircraft Industrial (Group) Co. Ltd., Chengdu 610092, China)

Funds: National Natural Science Foundation of China(51875284)

摘要

摘要: 平纹编织碳纤维增强树脂基复合材料(Plain-Woven Carbon Fiber-Reinforced Plastic，简称PW-CFRP)由于纤维间相互交错的几何结构，展现出高损伤容限特性，在航空航天领域应用广泛。国内外学者主要是开展了材料的力学性能试验或仿真研究，且仿真多聚焦在微观仿真层面，在切削加工方面研究更偏向于单向CFRP，同时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的去研究其切削机理。本文进一步完善了碳纤维复合材料切削加工的理论内容，为扩大PW-CFRP的应用范围提供理论支撑。本文根据PW-CFRP的几何结构特点建立了包含树脂基体相-界面相-纤维增强相的三维几何模型，并采用3D Hashin失效准则和PUCK基体失效准则，利用Fortran语言编写等效均质纤维束力学本构模型，建立介观尺度三维正交切削仿真模型。模拟了PW-CFRP的切屑形成过程，同时开展正交切削试验，对仿真模型进行验证；通过仿真分析结合实验阐明了在PW-CFRP中，纤维切削角对材料去除机理的影响以及经纬纤维束之间的相互钳制作用。其中不同纤维方向的纤维束区域最大损伤深度依次为0°<45°<90°<135°；经纬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。同时，表面纤维附近树脂层厚度是加工表面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，使得材料表面损伤呈弧形分布。1(0°/90°)铺层织物正交切削切屑形成过程2纤维束受力情形与表面损伤形成
- 平纹编织结构CFRP /
- ABAQUS /
- 正交切削 /
- 纤维方向 /
- 材料去除机理
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.
- plain woven CFRP /
- ABAQUS /
- orthogonal cutting /
- fiber orientation /
- material removal mechanism

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图 1 PW-CFRP截面实物图与结构示意图

Figure 1. Physical and structural diagram of PW-CFRP section

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图 2 PW-CFRP三维几何模型

Figure 2. Three-dimensional geometric model of PW-CFRP

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图 3 PW-CFRP正交切削仿真模型及纤维束材料主方向

Figure 3. Orthogonal cutting simulation model of PW-CFRP and main material direction of fiber bundle

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图 4 树脂基体材料本构

Figure 4. Constitutive model of matrix material

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图 5 Cohesive粘性表面本构

Figure 5. Constitutive model of Cohesive surface

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图 6 界面层的壳单元模型

Figure 6. Shell element model of interface layer

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图 7 PW-CFRP正交切削试验平台及刀具示意图

Figure 7. Orthogonal cutting experiment platform of PW-CFRP and tool diagram

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图 8 PW-CFRP切削力仿真与试验结果对比(v=2000 mm·min⁻¹，a_p=0.1 mm)

Figure 8. Comparison of simulation force and experiment force results of PW-CFRP(v=2000 mm·min⁻¹，a_p=0.1 mm)

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图 9 PW-CFRP织物层最大损伤深度的仿真与试验结果(v=2000 mm·min⁻¹，a_p=0.1 mm)

Figure 9. PW-CFRP fabric layer simulation and experiment results of maximum damage depth(v=2000 mm·min⁻¹，a_p=0.1 mm

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图 10 PW-CFRP(0°/90°)织物层纤维束的切屑形成过程

Figure 10. Chip formation process of PW-CFRP (0°/90°) fabric layer

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图 11 PW-CFRP(45°/135°)织物层纤维束的切屑形成过程

Figure 11. Chip formation process of PW-CFRP (45°/135°) fabric layer

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图 12 PW-CFRP中树脂厚度分布示意图

Figure 12. Matrix thickness distribution in PW-CFRP

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图 13 表面PW-CFRP织物在切削载荷下的受力情形示意图

Figure 13. Force analysis of surface PW-CFRP fabric under cutting load

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图 14 PW-CFRP(0°/90°)织物层材料表面损伤形成机制

Figure 14. PW-CFRP ( 0° / 90° ) fabric layer material removal mechanism

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图 15 PW-CFRP(45°/135°)织物层材料表面损伤形成机制

Figure 15. PW-CFRP ( 45° / 135° ) fabric layer material removal mechanism

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表 1 仿真模型几何尺寸参数

Table 1. Geometric dimension parameters of simulation model

A₀/mm	H₀/mm	V_f	h₀/mm
1.8	0.15	55%	0.05
Notes：A₀ is fiber bundle width; H₀ the maximum thickness of fiber bundle interface; V_f is fiber volume fraction; h₀ is the thickness of resin-starved area.

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表 2 T700碳纤维织物材料各组分性能参数^[27-30]

Table 2. Property parameters of each component of T700 carbon fiber fabric^[27-30]

Phase composition	Material parameter	Value
Fiber bundle	X_{1 t}^f/MPa	4900
	X_{1 c}^f/MPa	4500
	X_{2 t}^f/MPa	400
	X_{2 c}^f/MPa	700
	X_{3 t}^f/MPa	400
	X_{3 c}^f/MPa	700
	S₁₂^f/MPa	100
	S₁₃/MPa	100
	S₂₃^f/MPa	58
Matrix	ρ_m/(kg·m⁻³)	980
	E_m/MPa	4000
	ν_m	0.4
	σ_y0^m /MPa	270
Interface properties	N_max/MPa	60
	S_max/MPa	90
	T_max/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：X_{1 t}^f—Tensile strength of fiber bundles in 1 direction; X_{2 t}^f—Tensile strength of fiber bundles in 2 directions; X_{3 t}^f—Tensile strength of fiber bundles in 3 directions; X_{1 c}^f— Compressive strength of fiber bundles in the 1 direction; X_{2 c}^f—Compressive strength of fiber bundles in 2 directions; X_{3 c}^f—Compressive strength of fiber bundles in 3 directions; S₁₂^f—Shear strength of fiber bundles in 1-2 plane; S₂₃^f—Shear strength of fiber bundles in 2-3 planes; S₁₃^f—Shear strength of fiber bundles in 1-3 planes. ρ_m is matrix density; E_m is Young 's modulus of matrix;ν_m is Poisson 's ratio of matrix; σ_y0^m is yield strength of the matrix; N_max is normal stress intensity of interface; S_max is first tangential stress intensity of interface; T_max is second tangential stress intensity of interface; $ {G}_{\mathrm{n}}^{\mathrm{c}} $is normal critical fracture energy of interface; $ {G}_{\mathrm{s}}^{\mathrm{c}} $ is first tangential critical fracture energy of interface; $ {G}_{\mathrm{t}}^{\mathrm{c}} $ is second tangential critical fracture energy of interface.

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表 3 正交切削试验参数

Table 3. Process parameters of orthogonal cutting experiment

v/(mm·min⁻¹)	a_p/mm	γ/(°)	α/(°)
2000	0.1	15	12
Notes: v is cutting speed; a_p is cutting depth; γ is working orthogonal rake of tool; α is working back angle of tool.

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