Factor analysis of machining parameters of fiber-reinforced polymer composites based on finite element simulation with experimental investigation
Factor analysis of machining parameters of fiber-reinforced polymer composites based on finite element simulation with experimental investigation
复制标题
基于有限元模拟与实验研究的纤维增强聚合物复合材料加工参数因子分析
DOI：
10.1007/s00170-015-7592-2
复制
发表时间：
2016-03-01
影响因子：
3.4
通讯作者：
Ke, Yinglin
中科院分区：
文献类型：
--
作者：
Gao, Chongyang;Xiao, Jianzhang;Ke, Yinglin
建立了纤维增强复合材料（FRP）加工的三维细观力学有限元模型。有限元建模考虑了复合材料的三个相，其中纤维和基体之间的界面可以实现界面脱粘来表示复合材料的失效并允许热传递。首先对碳纤维增强聚合物（CFRP）复合材料在不同纤维取向下的加工表面进行观察和表面粗糙度测量，然后将模型预测的不同纤维取向下的切削力、温度和表面粗糙度等加工响应与各种实验数据进行比较，以验证模型的有效性。结果表明，三相细观力学模型能够精确地预测切削响应，并描述切屑形成过程中与纤维取向相关的纤维剪切或弯曲失效模式。为研究多个加工参数对CFRP复合材料关键响应的复杂耦合影响，首先对各加工参数进行单因素分析，通过正交试验设计和方差分析，对多个加工参数进行了多因素分析定量比较这些关键加工参数对切削力和表面粗糙度的影响。结果表明，纤维取向角、切削深度和切削速度是影响切削力和表面粗糙度的重要因素，在CFRP复合材料的加工过程中，这些加工参数的耦合效应相对可以忽略。
A three-dimensional (3D) micromechanical finite element (FE) model of machining of fiber-reinforced polymer (FRP) composites was developed in the paper. The FE modeling considers the three phases of a composite, in which the interphase between the fiber and matrix can realize interfacial debonding to represent the failure of composites and allow heat transfer. The machined surface observations and surface roughness measurements of carbon fiber-reinforced polymer (CFRP) composites at different fiber orientations were done firstly, and then, the model predictions of the machining responses, such as cutting force, temperature, and surface roughness, at different fiber orientations were compared with various experimental data for model validation. It is indicated that the three-phase micromechanical model is capable of precisely predicting machining responses and describing the failure modes of fiber shearing or bending related with fiber orientations in the chip formation process. To investigate the complex coupling influences of multiple machining parameters on the key responses of CFRP composites, the single-factor analyses of each machining parameter were first carried out, and then, the multi-factorial analysis of multiple machining parameters was performed based on the orthogonal design of experiment and the analysis of variance (ANOVA) to quantitatively compare the influences of these key machining parameters on the cutting force and surface roughness. It was found that the fiber orientation angle, depth of cut, and cutting speed prove to be the important factors affecting the cutting force and surface roughness and that the coupling effects of these machining parameters all are relatively negligible in the machining of CFRP composites.