Three-dimensional macro-mechanical finite element model for machining of unidirectional-fiber reinforced polymer composites

A three-dimensional macro-mechanical finite element (FE) model is developed to study the machining response of unidirectional (UD) carbon fiber reinforced polymer composites. This study is conducted for a range of fiber orientations, depths of cut and rake angles both experimentally as well as numerically. In the FE model the material properties are assumed as degraded based on the three-dimensional Tsai-Hill failure criterion. Cutting/thrust forces obtained from the FE simulation matches well with the experimental observations. Cutting force increases with fiber orientation and depth of cut but is less influenced by rake angle. Chip formation mechanism is observed under an optical microscope and is compared with FE simulation results. The chip formation mechanism predicted by FE simulations has a good agreement with experimental observations.