Finite element analysis when machining UGF-reinforced PMCs plates: Chip formation, crack propagation and induced-damage

This paper presents a novel model for simulation of polymer-matrix composites (PMCs). The model is developed for orthogonal cutting configuration and finite element analysis (FEA). For enhancing chip formation simulation, adaptive mesh technique and dynamic explicit elements are used. The assumption of equivalent homogeneous material (EHM) is considered for modelling the composite plate. The model assumes plane stress state and orthotropic behaviour. The failure mechanism is modelled by the Tsai-Hill criterion. Comparison between the current results and experimental findings yields better agreement than the numerical model proposed in literature by Nayak et al. [Nayak D, Bhatnagar N, Mahajan P. Machining studies of UD-FRP composites. Part 1: Effect of geometrical and process parameters. Mach Sci Technol 2005;9(4):481–501]. The failure envelopes have served to examine the damage generated in the sub-surface, below the trim plane. Sensitivity of chip formation mechanism and damage generation on the fibre orientation is confirmed. The current model showed real enhancement over the model proposed by Nayak et al.