A multi-phase and a continuum based finite element model using the commercial finite element package ABAQUS is developed for simulating the orthogonal machining of composite materials. The materials considered for this study are a glass fiber reinforced epoxy composite and a ceramic matrix composite. The effect of varying the fiber orientation and tool rake angle on the cutting force, temperature distribution and damage during machining are considered. In the multi-phase approach the fiber and matrix are modeled as continuum elements with isotropic properties separated by an interfacial layer while the tool is modeled as a rigid body. The cohesive zone modeling approach is used for the interfacial layer. Bulk deformation and shear failure is considered in the fiber and matrix while the traction separation in the cohesive zone is used to ascertain the extent of delamination below the work surface. For validation purposes simulation results of the multi-phase approach are compared with experimental measurements. Parametric studies are conducted utilizing the equivalent homogenous (EHM) material model. The EHM simplifies the composite material into an anisotropic but locally homogenous material. External heating effect on the workpiece is considered in the EHM model to include preliminary results on Laser Assisted Machining. The model is successful in predicting cutting forces, temperature distribution entry and exit damage with respect to the fiber orientation.

This content is only available via PDF.
You do not currently have access to this content.