Numerical simulation of milling operations on flexible composite parts

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.