Factor analysis of machining parameters of fiber-reinforced polymer composites based on finite element simulation with experimental investigation

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• 作者：Chongyang Gao ; Jianzhang Xiao ; Jiuhua Xu…
• 关键词：Factor analysis ; Machining parameters ; Fiber ; reinforced polymer (FRP) composite ; Micromechanical finite element (FE) modeling ; Surface measurement
• 刊名：The International Journal of Advanced Manufacturing Technology
• 出版年：2016
• 出版时间：March 2016
• 年：2016
• 卷：83
• 期：5-8
• 页码：1113-1125
• 全文大小：2,491 KB
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• 作者单位：Chongyang Gao (1)
  Jianzhang Xiao (1)
  Jiuhua Xu (2)
  Yinglin Ke (1)
  
  1. The State Key Laboratory of Fluid Power Transmission and Control, College of Mechanical Engineering, Zhejiang University, Hangzhou, 310027, China
  2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, Nanjing, 210000, China
  
• 刊物类别：Engineering
• 刊物主题：Industrial and Production Engineering
  Production and Logistics
  Mechanical Engineering
  Computer-Aided Engineering and Design
  
• 出版者：Springer London
• ISSN：1433-3015

文摘

A three-dimensional (3D) micromechanical finite element (FE) model of machining of fiber-reinforced polymer (FRP) composites was developed in the paper. The FE modeling considers the three phases of a composite, in which the interphase between the fiber and matrix can realize interfacial debonding to represent the failure of composites and allow heat transfer. The machined surface observations and surface roughness measurements of carbon fiber-reinforced polymer (CFRP) composites at different fiber orientations were done firstly, and then, the model predictions of the machining responses, such as cutting force, temperature, and surface roughness, at different fiber orientations were compared with various experimental data for model validation. It is indicated that the three-phase micromechanical model is capable of precisely predicting machining responses and describing the failure modes of fiber shearing or bending related with fiber orientations in the chip formation process. To investigate the complex coupling influences of multiple machining parameters on the key responses of CFRP composites, the single-factor analyses of each machining parameter were first carried out, and then, the multi-factorial analysis of multiple machining parameters was performed based on the orthogonal design of experiment and the analysis of variance (ANOVA) to quantitatively compare the influences of these key machining parameters on the cutting force and surface roughness. It was found that the fiber orientation angle, depth of cut, and cutting speed prove to be the important factors affecting the cutting force and surface roughness and that the coupling effects of these machining parameters all are relatively negligible in the machining of CFRP composites.