Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite

Jia Ge; Wei Tan; Shahzad Ahmad; Brian G. Falzon; Giuseppe Catalanotti; Colm Higgins; Yan Jin; Dan Sun

doi:10.1016/j.compositesa.2023.107820

Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite

Jia Ge, Wei Tan, Shahzad Ahmad, Brian G. Falzon, Giuseppe Catalanotti, Colm Higgins, Yan Jin, Dan Sun

Research output: Contribution to journal › Article › peer-review

24 Citations (Scopus)

Abstract

The global commitment towards reducing carbon emissions drives the implementation of sustainable carbon-fibre-reinforced-thermoplastic composites (CFRTPs). However, the machining of CFRTPs presents challenges due to the material's ductile–brittle composition and sensitivity to machining-induced high temperatures. For the first time, we conducted temperature-controlled orthogonal cutting of CFRTP (using CF/PEKK as a demonstrator) to unveil its temperature-dependent cutting physics. Three representative cutting temperatures, 23 ℃ (ambient temperature),100 ℃ (<PEKK's glass transition temperature (T_g)) and 200 ℃ (>T_g) and four typical fibre cutting orientations (0°, 45°, 90°, and 135°) have been investigated. The evolution of chip microstructural morphology and surface/subsurface damage have been analysed by advanced microscopy to reveal temperature-dependent material removal mechanisms. The experimental results were elucidated through a novel microscale finite-element-analysis (FEA) model considering thermal softening of the matrix and interface. Results show the transition of the cutting physics with increasing temperature is associated to the degradation of the thermoplastic matrix stiffness/ultimate strength and interface bonding strength and fracture toughness, especially when > T_g.

Original language	English
Article number	107820
Number of pages	19
Journal	Composites. Part A, Applied Science and Manufacturing
Volume	176
DOIs	https://doi.org/10.1016/j.compositesa.2023.107820 https://doi.org/10.1016/j.compositesa.2023.107820
Publication status	Published - Jan 2024
Externally published	Yes

Bibliographical note

Publisher Copyright:
© 2023 The Author(s)

Open Access - Access Right Statement

Keywords

Cutting
Finite element analysis (FEA)
High-temperature properties
Thermoplastic resin

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Ge, J., Tan, W., Ahmad, S., Falzon, B. G., Catalanotti, G., Higgins, C., Jin, Y., & Sun, D. (2024). Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite. Composites. Part A, Applied Science and Manufacturing, 176, Article 107820. https://doi.org/10.1016/j.compositesa.2023.107820, https://doi.org/10.1016/j.compositesa.2023.107820

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title = "Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite",

abstract = "The global commitment towards reducing carbon emissions drives the implementation of sustainable carbon-fibre-reinforced-thermoplastic composites (CFRTPs). However, the machining of CFRTPs presents challenges due to the material's ductile–brittle composition and sensitivity to machining-induced high temperatures. For the first time, we conducted temperature-controlled orthogonal cutting of CFRTP (using CF/PEKK as a demonstrator) to unveil its temperature-dependent cutting physics. Three representative cutting temperatures, 23 ℃ (ambient temperature),100 ℃ (g)) and 200 ℃ (>Tg) and four typical fibre cutting orientations (0°, 45°, 90°, and 135°) have been investigated. The evolution of chip microstructural morphology and surface/subsurface damage have been analysed by advanced microscopy to reveal temperature-dependent material removal mechanisms. The experimental results were elucidated through a novel microscale finite-element-analysis (FEA) model considering thermal softening of the matrix and interface. Results show the transition of the cutting physics with increasing temperature is associated to the degradation of the thermoplastic matrix stiffness/ultimate strength and interface bonding strength and fracture toughness, especially when > Tg.",

keywords = "Cutting, Finite element analysis (FEA), High-temperature properties, Thermoplastic resin",

author = "Jia Ge and Wei Tan and Shahzad Ahmad and Falzon, {Brian G.} and Giuseppe Catalanotti and Colm Higgins and Yan Jin and Dan Sun",

note = "Publisher Copyright: {\textcopyright} 2023 The Author(s)",

year = "2024",

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doi = "10.1016/j.compositesa.2023.107820",

language = "English",

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Ge, J, Tan, W, Ahmad, S, Falzon, BG, Catalanotti, G, Higgins, C, Jin, Y & Sun, D 2024, 'Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite', Composites. Part A, Applied Science and Manufacturing, vol. 176, 107820. https://doi.org/10.1016/j.compositesa.2023.107820, https://doi.org/10.1016/j.compositesa.2023.107820

TY - JOUR

T1 - Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite

AU - Ge, Jia

AU - Tan, Wei

AU - Ahmad, Shahzad

AU - Falzon, Brian G.

AU - Catalanotti, Giuseppe

AU - Higgins, Colm

AU - Jin, Yan

AU - Sun, Dan

PY - 2024/1

Y1 - 2024/1

N2 - The global commitment towards reducing carbon emissions drives the implementation of sustainable carbon-fibre-reinforced-thermoplastic composites (CFRTPs). However, the machining of CFRTPs presents challenges due to the material's ductile–brittle composition and sensitivity to machining-induced high temperatures. For the first time, we conducted temperature-controlled orthogonal cutting of CFRTP (using CF/PEKK as a demonstrator) to unveil its temperature-dependent cutting physics. Three representative cutting temperatures, 23 ℃ (ambient temperature),100 ℃ (g)) and 200 ℃ (>Tg) and four typical fibre cutting orientations (0°, 45°, 90°, and 135°) have been investigated. The evolution of chip microstructural morphology and surface/subsurface damage have been analysed by advanced microscopy to reveal temperature-dependent material removal mechanisms. The experimental results were elucidated through a novel microscale finite-element-analysis (FEA) model considering thermal softening of the matrix and interface. Results show the transition of the cutting physics with increasing temperature is associated to the degradation of the thermoplastic matrix stiffness/ultimate strength and interface bonding strength and fracture toughness, especially when > Tg.

AB - The global commitment towards reducing carbon emissions drives the implementation of sustainable carbon-fibre-reinforced-thermoplastic composites (CFRTPs). However, the machining of CFRTPs presents challenges due to the material's ductile–brittle composition and sensitivity to machining-induced high temperatures. For the first time, we conducted temperature-controlled orthogonal cutting of CFRTP (using CF/PEKK as a demonstrator) to unveil its temperature-dependent cutting physics. Three representative cutting temperatures, 23 ℃ (ambient temperature),100 ℃ (g)) and 200 ℃ (>Tg) and four typical fibre cutting orientations (0°, 45°, 90°, and 135°) have been investigated. The evolution of chip microstructural morphology and surface/subsurface damage have been analysed by advanced microscopy to reveal temperature-dependent material removal mechanisms. The experimental results were elucidated through a novel microscale finite-element-analysis (FEA) model considering thermal softening of the matrix and interface. Results show the transition of the cutting physics with increasing temperature is associated to the degradation of the thermoplastic matrix stiffness/ultimate strength and interface bonding strength and fracture toughness, especially when > Tg.

KW - Cutting

KW - Finite element analysis (FEA)

KW - High-temperature properties

KW - Thermoplastic resin

UR - https://hdl.handle.net/1959.7/uws:75551

U2 - 10.1016/j.compositesa.2023.107820

DO - 10.1016/j.compositesa.2023.107820

M3 - Article

SN - 1359-835X

VL - 176

JO - Composites. Part A, Applied Science and Manufacturing

JF - Composites. Part A, Applied Science and Manufacturing

M1 - 107820

ER -

Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite

Abstract

Bibliographical note

Open Access - Access Right Statement

Keywords

Access to Document

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