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

doi:10.13801/j.cnki.fhclxb.20221214.001

平纹编织结构CFRP正交切削切屑形成及表面损伤

doi: 10.13801/j.cnki.fhclxb.20221214.001

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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- 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: 2022-12-16
- 刊出日期: 2023-09-15

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。
- 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.
- 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; h_m—Thickness of resin-rich area; φ—Fibre fluctuation angle

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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

σ₀—Resin yield stress; σ_y₀—Resin yield strength; E₀—Initial elastic modulus of resin; E_d—Elastic modulus of resin after degradation; d_m—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

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图 5 Cohesive黏性表面本构

Figure 5. Constitutive model of Cohesive surface

K—Interface separation stiffness; δ₀—Equivalent displacement at damage initiation; δ_f—Equivalent displacement when completely damaged; G_c—Interfacial fracture energy

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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

γ—Tool rake angle; α—Tool back angle

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图 8 PW-CFRP切削力仿真与试验结果对比(切削速度v=2000 mm·min⁻¹、切削深度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

D_max—Maximum damage depth; SDV3—Resin tensile failure damage output variable

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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

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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_1t ^f/MPa	4900
	X_1c ^f/MPa	4500
	X_2t ^f/MPa	400
	X_2c ^f/MPa	700
	X_3t ^f/MPa	400
	X_3c ^f/MPa	700
	S₁₂ ^f/MPa	100
	S₁₃ ^f/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_1t ^f—Tensile strength of fiber bundles in 1 direction; X_2t ^f—Tensile strength of fiber bundles in 2 direction; X_3t ^f—Tensile strength of fiber bundles in 3 direction; X_1c ^f—Compressive strength of fiber bundles in the 1 direction; X_2c ^f—Compressive strength of fiber bundles in 2 direction; X_3c ^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. ρ_m—Matrix density; E_m—Young's modulus of matrix; ν_m—Poisson's ratio of matrix; σ_y0 ^m—Yield strength of the matrix; N_max—Normal stress intensity of interface; S_max—First tangential stress intensity of interface; T_max—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.

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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/(°)
2 000	0.1	15	12
Notes: v—Cutting speed; a_p—Cutting depth.

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