A finite element model was developed to simulate chip formation in the edge trimming of unidirectional Fiber Reinforced Plastics (FRPs) with orthogonal cutting tools. Fiber orientations (θ) within the range of 0 deg⩽θ⩽90 deg were considered and the cutting tool was modeled as both a rigid and deformable body in independent simulations. The principal and thrust force history resulting from numerical simulations for orthogonal cutting were compared to those obtained from edge trimming of unidirectional Graphite/Epoxy (Gr/Ep) using polycrystalline diamond tools. It was found that principal cutting forces obtained from the finite element model with both rigid and deformable body tools compared well with experimental results. Although the cutting forces increased with increasing fiber orientation, the tool rake angle had limited influence on cutting forces for all orientations other than θ=0 deg and 90 deg. However, the tool geometry did affect the degree of subsurface damage resulting from interlaminar shear failure as well as the cutting tool stress distribution. The finite element model for chip formation provides a means for optimizing tool geometry over the total range in fiber orientations in terms of the cutting forces, degree of subsurface trimming damage, and the cutting tool stresses.
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February 2002
Technical Papers
Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics
D. Arola,
D. Arola
Department of Mechanical Engineering, University of Maryland, Baltimore County, 1000 Hilltop Circle, Baltimore, MD 21250
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M. B. Sultan,
M. B. Sultan
Department of Mechanical Engineering, University of Maryland, Baltimore County, 1000 Hilltop Circle, Baltimore, MD 21250
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M. Ramulu
M. Ramulu
Department of Mechanical Engineering, University of Washington, Box 352600, Seattle, WA 98195
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D. Arola
Department of Mechanical Engineering, University of Maryland, Baltimore County, 1000 Hilltop Circle, Baltimore, MD 21250
M. B. Sultan
Department of Mechanical Engineering, University of Maryland, Baltimore County, 1000 Hilltop Circle, Baltimore, MD 21250
M. Ramulu
Department of Mechanical Engineering, University of Washington, Box 352600, Seattle, WA 98195
Contributed by the Manufacturing Engineering Division for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received Dec. 1999; Revised Dec. 2000; Associate Editor: S. G. Kapoor.
J. Manuf. Sci. Eng. Feb 2002, 124(1): 32-41 (10 pages)
Published Online: December 1, 2000
Article history
Received:
December 1, 1999
Revised:
December 1, 2000
Citation
Arola , D., Sultan, M. B., and Ramulu, M. (December 1, 2000). "Finite Element Modeling of Edge Trimming Fiber Reinforced Plastics ." ASME. J. Manuf. Sci. Eng. February 2002; 124(1): 32–41. https://doi.org/10.1115/1.1428329
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