Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method

Jia Ge; Wei Tan; Giuseppe Catalanotti; Brian G Falzon; John McClelland; Colm Higgins; Yan Jin; Dan Sun; Mahmoud Shafik; Keith Case

doi:10.3233/ATDE220584

Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method

Jia Ge, Wei Tan, Giuseppe Catalanotti, Brian G Falzon, John McClelland, Colm Higgins, Yan Jin, Dan Sun, Mahmoud Shafik (Editor), Keith Case (Editor)

School of Engineering, Design & Built Environment

Research output: Chapter in Book / Conference Paper › Conference Paper › peer-review

7 Citations (Scopus)

Abstract

There has been an enormous increase in using of carbon fiber reinforced thermoplastic (CFRTP) especially carbon fiber reinforce polyetherketoneketone (CF/PEKK) in automotive and aeronautical industries. However, fundamental material removal mechanism of such material has never been elucidated in the literature. In this work, finite-element (FE) method is deployed and microscale numerical model considering fiber, matrix and interface has been established to understand the mechanisms of chip formation in orthogonal cutting of unidirectional (UD) thermoplastic CF/PEKK composites. Chip formation and subsequent surface / subsurface damage with different fiber orientations (0°, 45°, 90°, 135°) are modelled and compared. Results suggest that, for CF/PEKK, the chip formation mechanism is significantly affected by the fiber orientation and the most severe subsurface damage can be seen at fiber orientation 135°, as a result of bending fracture below the ideal machined surface.

Original language	English
Title of host publication	Moving Integrated Product Development to Service Clouds in the Global Economy - Proceedings of the 21st ISPE Inc. International Conference on Concurrent Engineering, CE 2014
Editors	Mahmoud Shafik, Keith Case
Place of Publication	Derby, UK
Publisher	IOS Press
Pages	161-166
Number of pages	6
Volume	25
ISBN (Electronic)	9781643683300
ISBN (Print)	978-1-64368-330-0
DOIs	https://doi.org/10.3233/ATDE220584
Publication status	Published - 8 Nov 2022

Publication series

Name	Advances in Transdisciplinary Engineering
Volume	25
ISSN (Print)	2352-751X
ISSN (Electronic)	2352-7528

Bibliographical note

19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6–8 September 2022, University of Derby, UK

Keywords

CF/PEKK CFRTP Orthogonal cutting Fibers Finite element method Reinforced plastics Automotives Carbon fiber reinforce polyetherketoneketone Carbon fiber reinforced Carbon fiber reinforced thermoplastic Chip formations Fiber reinforced thermoplastics Fibre orientation Material removal mechanisms Sub-surface damage Numerical methods
CF/PEKK
CFRTP
Orthogonal cutting

Access to Document

10.3233/ATDE220584

Cite this

Ge, J., Tan, W., Catalanotti, G., Falzon, B. G., McClelland, J., Higgins, C., Jin, Y., Sun, D., Shafik, M. (Ed.), & Case, K. (Ed.) (2022). Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method. In M. Shafik, & K. Case (Eds.), Moving Integrated Product Development to Service Clouds in the Global Economy - Proceedings of the 21st ISPE Inc. International Conference on Concurrent Engineering, CE 2014 (Vol. 25, pp. 161-166). (Advances in Transdisciplinary Engineering; Vol. 25). IOS Press. https://doi.org/10.3233/ATDE220584

Ge, Jia ; Tan, Wei ; Catalanotti, Giuseppe et al. / Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method. Moving Integrated Product Development to Service Clouds in the Global Economy - Proceedings of the 21st ISPE Inc. International Conference on Concurrent Engineering, CE 2014. editor / Mahmoud Shafik ; Keith Case. Vol. 25 Derby, UK : IOS Press, 2022. pp. 161-166 (Advances in Transdisciplinary Engineering).

@inproceedings{8f275766a8564414adf3fe8f59f2d3b2,

title = "Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method",

abstract = "There has been an enormous increase in using of carbon fiber reinforced thermoplastic (CFRTP) especially carbon fiber reinforce polyetherketoneketone (CF/PEKK) in automotive and aeronautical industries. However, fundamental material removal mechanism of such material has never been elucidated in the literature. In this work, finite-element (FE) method is deployed and microscale numerical model considering fiber, matrix and interface has been established to understand the mechanisms of chip formation in orthogonal cutting of unidirectional (UD) thermoplastic CF/PEKK composites. Chip formation and subsequent surface / subsurface damage with different fiber orientations (0°, 45°, 90°, 135°) are modelled and compared. Results suggest that, for CF/PEKK, the chip formation mechanism is significantly affected by the fiber orientation and the most severe subsurface damage can be seen at fiber orientation 135°, as a result of bending fracture below the ideal machined surface.",

keywords = "CF/PEKK CFRTP Orthogonal cutting Fibers Finite element method Reinforced plastics Automotives Carbon fiber reinforce polyetherketoneketone Carbon fiber reinforced Carbon fiber reinforced thermoplastic Chip formations Fiber reinforced thermoplastics Fibre orientation Material removal mechanisms Sub-surface damage Numerical methods, CF/PEKK, CFRTP, Orthogonal cutting",

author = "Jia Ge and Wei Tan and Giuseppe Catalanotti and Falzon, {Brian G} and John McClelland and Colm Higgins and Yan Jin and Dan Sun and Mahmoud Shafik and Keith Case",

note = "19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6–8 September 2022, University of Derby, UK",

year = "2022",

month = nov,

day = "8",

doi = "10.3233/ATDE220584",

language = "English",

isbn = "978-1-64368-330-0",

volume = "25",

series = "Advances in Transdisciplinary Engineering",

publisher = "IOS Press",

pages = "161--166",

editor = "Mahmoud Shafik and Keith Case",

booktitle = "Moving Integrated Product Development to Service Clouds in the Global Economy - Proceedings of the 21st ISPE Inc. International Conference on Concurrent Engineering, CE 2014",

}

Ge, J, Tan, W, Catalanotti, G, Falzon, BG, McClelland, J, Higgins, C, Jin, Y, Sun, D, Shafik, M (ed.) & Case, K (ed.) 2022, Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method. in M Shafik & K Case (eds), Moving Integrated Product Development to Service Clouds in the Global Economy - Proceedings of the 21st ISPE Inc. International Conference on Concurrent Engineering, CE 2014. vol. 25, Advances in Transdisciplinary Engineering, vol. 25, IOS Press, Derby, UK, pp. 161-166. https://doi.org/10.3233/ATDE220584

Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method. / Ge, Jia; Tan, Wei; Catalanotti, Giuseppe et al.
Moving Integrated Product Development to Service Clouds in the Global Economy - Proceedings of the 21st ISPE Inc. International Conference on Concurrent Engineering, CE 2014. ed. / Mahmoud Shafik; Keith Case. Vol. 25 Derby, UK: IOS Press, 2022. p. 161-166 (Advances in Transdisciplinary Engineering; Vol. 25).

Research output: Chapter in Book / Conference Paper › Conference Paper › peer-review

TY - GEN

T1 - Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method

AU - Ge, Jia

AU - Tan, Wei

AU - Catalanotti, Giuseppe

AU - Falzon, Brian G

AU - McClelland, John

AU - Higgins, Colm

AU - Jin, Yan

AU - Sun, Dan

A2 - Shafik, Mahmoud

A2 - Case, Keith

A2 - Shafik, Mahmoud

A2 - Case, Keith

N1 - 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6–8 September 2022, University of Derby, UK

PY - 2022/11/8

Y1 - 2022/11/8

N2 - There has been an enormous increase in using of carbon fiber reinforced thermoplastic (CFRTP) especially carbon fiber reinforce polyetherketoneketone (CF/PEKK) in automotive and aeronautical industries. However, fundamental material removal mechanism of such material has never been elucidated in the literature. In this work, finite-element (FE) method is deployed and microscale numerical model considering fiber, matrix and interface has been established to understand the mechanisms of chip formation in orthogonal cutting of unidirectional (UD) thermoplastic CF/PEKK composites. Chip formation and subsequent surface / subsurface damage with different fiber orientations (0°, 45°, 90°, 135°) are modelled and compared. Results suggest that, for CF/PEKK, the chip formation mechanism is significantly affected by the fiber orientation and the most severe subsurface damage can be seen at fiber orientation 135°, as a result of bending fracture below the ideal machined surface.

AB - There has been an enormous increase in using of carbon fiber reinforced thermoplastic (CFRTP) especially carbon fiber reinforce polyetherketoneketone (CF/PEKK) in automotive and aeronautical industries. However, fundamental material removal mechanism of such material has never been elucidated in the literature. In this work, finite-element (FE) method is deployed and microscale numerical model considering fiber, matrix and interface has been established to understand the mechanisms of chip formation in orthogonal cutting of unidirectional (UD) thermoplastic CF/PEKK composites. Chip formation and subsequent surface / subsurface damage with different fiber orientations (0°, 45°, 90°, 135°) are modelled and compared. Results suggest that, for CF/PEKK, the chip formation mechanism is significantly affected by the fiber orientation and the most severe subsurface damage can be seen at fiber orientation 135°, as a result of bending fracture below the ideal machined surface.

KW - CF/PEKK CFRTP Orthogonal cutting Fibers Finite element method Reinforced plastics Automotives Carbon fiber reinforce polyetherketoneketone Carbon fiber reinforced Carbon fiber reinforced thermoplastic Chip formations Fiber reinforced thermoplastics Fibre

KW - CF/PEKK

KW - CFRTP

KW - Orthogonal cutting

UR - http://www.scopus.com/inward/record.url?scp=85145572404&partnerID=8YFLogxK

U2 - 10.3233/ATDE220584

DO - 10.3233/ATDE220584

M3 - Conference Paper

SN - 978-1-64368-330-0

VL - 25

T3 - Advances in Transdisciplinary Engineering

SP - 161

EP - 166

BT - Moving Integrated Product Development to Service Clouds in the Global Economy - Proceedings of the 21st ISPE Inc. International Conference on Concurrent Engineering, CE 2014

PB - IOS Press

CY - Derby, UK

ER -

Ge J, Tan W, Catalanotti G, Falzon BG, McClelland J, Higgins C et al. Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method. In Shafik M, Case K, editors, Moving Integrated Product Development to Service Clouds in the Global Economy - Proceedings of the 21st ISPE Inc. International Conference on Concurrent Engineering, CE 2014. Vol. 25. Derby, UK: IOS Press. 2022. p. 161-166. (Advances in Transdisciplinary Engineering). doi: 10.3233/ATDE220584

Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method

Abstract

Publication series

Bibliographical note

Keywords

Access to Document

Other files and links

Fingerprint

Cite this