Numerical simulation of milling operations on flexible composite parts

Numerical simulation of milling operations on flexible composite parts

NUTTE Matthias, RIVIÈRE-LORPHÈVRE Edouard, DAMBLY Valentin, ARRAZOLA Pedro-José, LAZOGLU Ismail, DUCOBU François

download PDF

Abstract. Fiber-reinforced polymers (FRPs) are a widely used and growing material in industry, thanks to their excellent mechanical properties. Manufactured FRPs parts usually have thin walls. These parts also require finishing operations such as edge trimming. Problems like those encountered when machining thin metal parts are also encountered with FRPs: form error, chatter vibrations and poor surface finish. However, the study and numerical modelling of thin FRP parts are not well developed up to now. The aim of this paper is to demonstrate the feasibility of adapting a numerical model for metals to FRPs. The modelling of the shape error during the thinning of a CFRP (Carbon Fiber Reinforced Polymers) part is studied in this paper using a quasi-static analysis. Compared to metals, two adaptations are introduced here for the FRPs. First, the material properties are adapted from isotropic to orthotropic. Secondly, a mechanical model was applied to calculate cutting forces for FRPs. The results of the study show the feasibility of this adaptation and examination of form error in the case of FRPs.

Machining, Milling, CFRP, Flexible Parts, Form Error

Published online 4/24/2024, 9 pages
Copyright © 2024 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: NUTTE Matthias, RIVIÈRE-LORPHÈVRE Edouard, DAMBLY Valentin, ARRAZOLA Pedro-José, LAZOGLU Ismail, DUCOBU François, Numerical simulation of milling operations on flexible composite parts, Materials Research Proceedings, Vol. 41, pp 2041-2049, 2024


The article was published as article 225 of the book Material Forming

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

[1] J. Du, M. Geng, W. Ming, W. He, and J. Ma, ‘Simulation machining of fiber-reinforced composites: A review’, Int. J. Adv. Manuf. Technol., vol. 117, no. 1–2, pp. 1–15, Jul. 2021.
[2] I. Del Sol, A. Rivero, L. N. López de Lacalle, and A. J. Gamez, ‘Thin-Wall Machining of Light Alloys: A Review of Models and Industrial Approaches’, Materials, vol. 12, no. 12, Art. no. 12, Jan. 2019.
[3] I. Llanos, A. Robles, J. Condón, M. Arizmendi, and A. Beristain, ‘Deflection error modeling during thin-wall machining’, Procedia CIRP, vol. 117, pp. 169–174, 2023.
[4] E. Rivière-Lorphèvre, E. Filippi, and P. Dehombreux, ‘Numerical Simulation of Machining Operations on Flexible Parts’, Key Eng. Mater., vol. 554–557, pp. 1984–1991, Jun. 2013.
[5] K. Kecik, R. Rusinek, J. Warminski, and A. Weremczuk, ‘Chatter control in the milling process of composite materials’, J. Phys. Conf. Ser., vol. 382, no. 1, p. 012012, Aug. 2012.
[6] K. Ciecieląg and K. Zaleski, ‘Milling of Three Types of Thin-Walled Elements Made of Polymer Composite and Titanium and Aluminum Alloys Used in the Aviation Industry’, Mater. 1996-1944, vol. 15, no. 17, p. 5949, Sep. 2022.
[7] Y. Song, H. Cao, W. Zheng, D. Qu, L. Liu, and C. Yan, ‘Cutting force modeling of machining carbon fiber reinforced polymer (CFRP) composites: A review’, Compos. Struct., vol. 299, p. 116096, Nov. 2022.
[8] G. V. G. Rao, P. Mahajan, and N. Bhatnagar, ‘Micro-mechanical modeling of machining of FRP composites – Cutting force analysis’, Compos. Sci. Technol., vol. 67, no. 3, pp. 579–593, Mar. 2007.
[9] R. Rentsch, O. Pecat, and E. Brinksmeier, ‘Macro and micro process modeling of the cutting of carbon fiber reinforced plastics using FEM’, Procedia Eng., vol. 10, pp. 1823–1828, Jan. 2011.
[10] D. Iliescu, D. Gehin, I. Iordanoff, F. Girot, and M. E. Gutiérrez, ‘A discrete element method for the simulation of CFRP cutting’, Compos. Sci. Technol., vol. 70, no. 1, pp. 73–80, Jan. 2010.
[11] H. N. Huynh, E. Rivière-Lorphèvre, F. Ducobu, A. Ozcan, and O. Verlinden, ‘Dystamill: a framework dedicated to the dynamic simulation of milling operations for stability assessment’, Int. J. Adv. Manuf. Technol., vol. 98, no. 5–8, pp. 2109–2126, Sep. 2018.
[12] D. Gay, Matériaux composites, 6e éd. revue et augmentée. Paris: Lavoisier Hermès, 2015.
[13] O. C. Zienkiewicz, The finite element method, 3., Expanded and rev. Ed.. reprint. London Hamburg: McGraw-Hill, 1986.
[14] B. Castanié, C. Bouvet, and D. Guedra-Degeorges, ‘Structures en matériaux composites stratifiés’, Concept. Prod., Oct. 2013.
[15] R. Mullin, M. Farhadmanesh, A. Ahmadian, and K. Ahmadi, ‘Modeling and identification of cutting forces in milling of Carbon Fibre Reinforced Polymers’, J. Mater. Process. Technol., vol. 280, p. 116595, Jun. 2020.
[16] Y. Altintaş and P. Lee, ‘A General Mechanics and Dynamics Model for Helical End Mills’, CIRP Ann., vol. 45, no. 1, pp. 59–64, Jan. 1996.
[17] P. D. Soden, M. J. Hinton, and A. S. Kaddour, ‘Lamina properties, lay-up configurations and loading conditions for a range of fibre-reinforced composite laminates’, Compos. Sci. Technol., pp. 1011–1022, Mar. 1998.