3D Progressive Damage Based Macro-Mechanical FE Simulation of Machining Unidirectional FRP Composite

Finite element(FE) simulation is a powerful tool for investigating the mechanism of machining fiber?reinforced polymer composite(FRP). However in existing FE machining simulation works,the two?dimensional(2 D) progressive damage models only describe material behavior in plane stress,while the three?dimensional(3 D) damage models always assume an instantaneous sti ness reduction pattern. So the chip formation mechanism of FRP under machin?ing is not fully analyzed in general stress state. A 3 D macro?mechanical based FE simulation model was developed for the machining of unidirectional glass fiber reinforced plastic. An energy based 3 D progressive damage model was proposed for damage evolution and continuous sti ness degradation. The damage model was implemented for the Hashin?type criterion and Maximum stress criterion. The influences of the failure criterion and fracture energy dissipa?tion on the simulation results were studied. The simulated chip shapes,cutting forces and sub?surface damages were verified by those obtained in the reference experiment. The simulation results also show consistency with previous 2 D FE models in the reference. The proposed research provides a model for simulating FRP material behavior and the machining process in 3 D stress state.

Progressive failure analysis of notched composite plate by utilizing macro mechanics approach

In this study,gradual and sudden reduction methods were combined to simulate a progressive failure in notched composite plates using a macro mechanics approach.Using the presented method,a progressive failure is simulated based on a linear softening law prior to a catastrophic failure,and thereafter,sudden reduction methods are employed for modeling a progressive failure.This combination method significantly reduces the computational cost and is also capable of simultaneously predicting the first and last ply failures(LPFs)in composite plates.The proposed method is intended to predict the first ply failure(FPF),LPF,and dominant failure modes of carbon/epoxy and glass/epoxy notched composite plates.In addition,the effects of mechanical properties and different stacking sequences on the propagation of damage in notched composite plates were studied.The results of the presented method were compared with experimental data previously reported in the literature.By comparing the numerical and experimental data,it is revealed that the proposed method can accurately simulate the failure propagation in notched composite plates at a low computational cost.