Abstract
In the paper, a three-dimensional (3D) micromechanical finite element (FE) cutting model with three phases was developed to study the surface integrity of CFRP composites. The surface roughness and the depth of subsurface damage were predicted by using the FE cutting model, which were used to characterize the surface integrity. The machined surface observations and surface roughness measurements of CFRP composites at different fiber orientations were also performed for model validation. It is indicated that the 3D micromechanical model is capable of precisely predicting the surface integrity of CFRP composites. To investigate the complex coupling influences of multiple machining parameters on the surface integrity, the factor analysis of multiple machining parameters was performed, and then the effects of these machining parameters on the surface roughness and subsurface damage depth were obtained quantitatively. It was found that the fiber orientation angle and cutting speed are the most significant factors affecting the surface roughness, and the fiber orientation and edge radius are the main factors affecting the subsurface damage depth. The results also reveal that coupling effects of depth of cut and edge radius should be considered for improving the surface integrity of CFRP composites.
Factor Analysis of Machining Parameters On Surface Integrity of CFRP Composites Based On A Microscopic Finite Element Cutting Model
