Simulation and experimental study of CFRTP orthogonal cutting considering the influence of temperature

Carbon fiber reinforced thermoplastic polymer (CFRTP) is the preferred material for weight loss and efficiency improvement of high-end equipment. However, CFRTP is a typical difficult-to-machine material, and damage occurs frequently during processing. In this paper, the process of material removal and damage formation during cutting CFRTP was simulated and experimentally studied. CFRTP is prone to plastic deformation during cutting, and the material properties are greatly affected by temperature. In this paper, a three-dimensional orthogonal cutting simulation model of CFRTP was established, and the J-C model was introduced to characterize the elastic-plastic deformation of resin at different temperatures. The effects of temperature and fiber orientation angle on the cutting removal process of CFRTP were analyzed. The results show that when cutting at room temperature, and the fiber orientation angles are 0° and 45°, the machined surface is relatively flat and the processing quality is better; When the fiber orientation angles are 90° and 135°, the bending degree of the fiber increases obviously, and there are cracks on the machined surface, and the processing quality is poor. When cutting at room temperature, and the fiber orientation angle is 0°, the unremoved material appears on the machined surface; when the fiber orientation angle is 45°, cracks and fiber pull-out phenomenon appear on the machined surface. When the fiber orientation angles are 90° and 135°, the machined surface is more cracked, and the workpiece has obvious out-of-plane deformation along the thickness direction. The material with out-of-plane deformation is difficult to be effectively removed. © 2024 Beijing University of Aeronautics and Astronautics (BUAA). All rights reserved.