Finite element analysis of the slot milling of carbon fiber reinforced polymer composites

• Published in: IOP conference series. Materials Science and Engineering 2021-04, Vol.1128 (1), p.12050
• Main Authors: Prakash, C, Vijay Sekar, K S
• Format: Article
• Language: English
• Subjects: Carbon fiber reinforced plastics; Carbon fiber reinforcement; Coefficient of friction; Cutting force; Cutting parameters; Cutting tools; Failure analysis; Fiber composites; Fiber reinforced polymers; Finite element method; Laminates; Mathematical models; Polymer matrix composites; Reliability analysis; Reliability aspects; Slot milling; Three dimensional models; Weight reduction
• ISSN: 1757-8981; 1757-899X
• DOI: 10.1088/1757-899X/1128/1/012050

Carbon Fiber Reinforced Polymer (CFRP) composites are widely used for making the components and primary structures in the field of aircraft, aerospace, automobile, medical, construction and many essential items which we use every day. These composite laminates are light in weight without compromising its strength. Hence, CFRP composites attract the researchers and the modern industries to investigate more on it. Industries rely on conventional machining process to achieve required shape and size, but CFRP composites show intrinsic behaviour while machining because of its non homogeneous properties. Selecting the appropriate tool and the cutting conditions for machining the CFRP composite, influences more in achieving the desired shape, size with close tolerance. In this paper, a 3D Finite Element Model is developed to simulate the slot milling process and to predict the cutting forces for the different cutting conditions. The reliability and accuracy of 3D FE analysis depend on the friction coefficient and failure model used in the FE model. These FE input parameters were applied in a wider range and analysis was carried out. The cutting forces obtained from the FE results are correlated with the experimental results to validate and to evaluate the influence of the FEM parameters. The outcome of this investigation is to suggest a suitable Failure model and the Friction coefficient, which ensures the reliability of the FE Model.