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

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

Queen's University Belfast
Queen Mary University of London
University of Évora
Royal Melbourne Institute of Technology University

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

10 Citations (Scopus)

57 Downloads (Pure)

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	Advances in Manufacturing Technology XXXV: Proceedings of the 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6-8 September 2022, University of Derby, Derby, UK
Editors	Mahmoud Shafik, Keith Case
Place of Publication	Netherlands
Publisher	IOS Press
Pages	161-166
Number of pages	6
ISBN (Electronic)	9781643683317
ISBN (Print)	9781643683300
DOIs	https://doi.org/10.3233/ATDE220584
Publication status	Published - 2022
Externally published	Yes
Event	International Conference on Manufacturing Research - University of Derby, Derby, United Kingdom Duration: 6 Sept 2022 → 8 Sept 2022 Conference number: 19th

Publication series

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

Conference

Conference	International Conference on Manufacturing Research
Country/Territory	United Kingdom
City	Derby
Period	6/09/22 → 8/09/22

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

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10.3233/ATDE220584Licence: CC BY-NC

Full text_chapterFinal published version, 1.36 MBLicence: CC BY-NC

Cite this

Ge, J., Tan, W., Catalanotti, G., Falzon, B. G., McClelland, J., Higgins, C., Jin, Y., & Sun, D. (2022). Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method. In M. Shafik, & K. Case (Eds.), Advances in Manufacturing Technology XXXV: Proceedings of the 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6-8 September 2022, University of Derby, Derby, UK (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. Advances in Manufacturing Technology XXXV: Proceedings of the 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6-8 September 2022, University of Derby, Derby, UK. editor / Mahmoud Shafik ; Keith Case. Netherlands : IOS Press, 2022. pp. 161-166 (Advances in Transdisciplinary Engineering).

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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",

year = "2022",

doi = "10.3233/ATDE220584",

language = "English",

isbn = "9781643683300",

series = "Advances in Transdisciplinary Engineering",

publisher = "IOS Press",

pages = "161--166",

editor = "Mahmoud Shafik and Keith Case",

booktitle = "Advances in Manufacturing Technology XXXV: Proceedings of the 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6-8 September 2022, University of Derby, Derby, UK",

note = "International Conference on Manufacturing Research ; Conference date: 06-09-2022 Through 08-09-2022",

}

Ge, J, Tan, W, Catalanotti, G, Falzon, BG, McClelland, J, Higgins, C, Jin, Y & Sun, D 2022, Understanding chip formation in orthogonal cutting of aeronautical thermoplastic CF/PEKK composites based on finite element method. in M Shafik & K Case (eds), Advances in Manufacturing Technology XXXV: Proceedings of the 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6-8 September 2022, University of Derby, Derby, UK. Advances in Transdisciplinary Engineering, vol. 25, IOS Press, Netherlands, pp. 161-166, International Conference on Manufacturing Research, Derby, United Kingdom, 6/09/22. 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.
Advances in Manufacturing Technology XXXV: Proceedings of the 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6-8 September 2022, University of Derby, Derby, UK. ed. / Mahmoud Shafik; Keith Case. Netherlands: IOS Press, 2022. p. 161-166 (Advances in Transdisciplinary Engineering; Vol. 25).

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

TY - CHAP

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

N1 - Conference code: 19th

PY - 2022

Y1 - 2022

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 - https://www.scopus.com/pages/publications/85145572404

U2 - 10.3233/ATDE220584

DO - 10.3233/ATDE220584

M3 - Chapter

SN - 9781643683300

T3 - Advances in Transdisciplinary Engineering

SP - 161

EP - 166

BT - Advances in Manufacturing Technology XXXV: Proceedings of the 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6-8 September 2022, University of Derby, Derby, UK

A2 - Shafik, Mahmoud

A2 - Case, Keith

PB - IOS Press

CY - Netherlands

T2 - International Conference on Manufacturing Research

Y2 - 6 September 2022 through 8 September 2022

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, Advances in Manufacturing Technology XXXV: Proceedings of the 19th International Conference on Manufacturing Research, Incorporating the 36th National Conference on Manufacturing Research, 6-8 September 2022, University of Derby, Derby, UK. Netherlands: 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

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