Machining simulation of composite materials using engineering simulation software

Abd Rahman, Zammeri (2014) Machining simulation of composite materials using engineering simulation software. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The milling process is one of the most important tool for cutting process in milling operation of composite material with the complex tool geometry. Composite materials are widely used in a variety of manufacturing sectors including the aerospace, marine and automotive industries. There is a lack of research on simulating the metal matrix composites using 3D Finite Element Methods (FEM) in the milling process and the 2D finite element methods cannot simulate the complex milling process. Therefore, an informative simulation study with more realistic 3D Finite Element Models (FEMs) as well as an orthogonal cutting model for the complex milling process of CFRP/AL2024 was developed to predict tool and workpiece using 3D Finite Element Analysis (FEA) with ABAQUS/EXPLICIT. Finally the results of stress distribution, milling temperatures, cutting force and chip formation are obtained. This model takes into account the dynamic effect, material damage law and contact criteria. This project also develops the 3D Model in Virtual Reality (VR) machining that to give an optimal solution of the tool path generation with the help of simulation using the VERICUT. Simulation and modelling of cutting processes have the potential for optimizing machining parameters and improving the cutting tool design, especially in advanced high-speed milling.

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