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<p>Carbon fibre reinforced plastics (CFRP) are prone to generating high cutting temperatures during machining, which makes cutting damage be induced frequently. Accurate predictions of the cutting temperature and damage distribution with numerical simulation will help to suppress the damage efficiently. In previous studies, numerical models have been proposed to analyse the cutting temperature and damage during CFRP cutting. However, the effects of cutting conditions have not been systematically investigated, and the interaction mechanism between cutting temperature and damage remains limited. To address this issue, a numerical model with thermo-mechanical coupling was proposed to research the temperature distribution and subsurface damage. The heat generation and transfer mechanisms during the cutting were involved. The CFRP were treated as an equivalent homogeneous material, with the damage initiation criteria and damage evolution laws defined. The degradation equations of the mechanical properties with temperature variation were formulated during the material modelling. Based on this numerical model, the predicted material removal process, cutting force, and machining temperature showed good agreement with experimental results in a validated thermal range of 303–315&#xa0;K. Then, the effects of the tool geometries and processing parameters on both the temperature distribution and subsurface damage depth were assessed. It was concluded that when the rake angle is positive, higher maximum temperature near the cutting edge (MT), smaller cutting forces and larger subsurface damage depths are produced under greater rake angles. The contact area and friction between the workpiece and the tool rake face are larger under greater cutting depth, resulting in an upward trend in workpiece temperature, and the cutting force and subsurface damage depth also increase with increasing depth of cut. At lower cutting speeds, smaller MTs and larger heat-affected zones are obtained, and the reduced cutting forces and subsurface damage depths are acquired under high cutting speeds.</p>

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Numerical Analysis of the Influences of Cutting Conditions on Temperature Distribution and Subsurface Damage in CFRP Cutting Based on Thermo-Mechanical Coupled Simulation

  • 期刊论文

  • 发表日期：

    2026年7月30日

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  • Guangjian Bi,
  • Xiaonan Wang,
  • Yongjun Shi,
  • Cheng Zhang,
  • Xuejin Zhao

摘要

Carbon fibre reinforced plastics (CFRP) are prone to generating high cutting temperatures during machining, which makes cutting damage be induced frequently. Accurate predictions of the cutting temperature and damage distribution with numerical simulation will help to suppress the damage efficiently. In previous studies, numerical models have been proposed to analyse the cutting temperature and damage during CFRP cutting. However, the effects of cutting conditions have not been systematically investigated, and the interaction mechanism between cutting temperature and damage remains limited. To address this issue, a numerical model with thermo-mechanical coupling was proposed to research the temperature distribution and subsurface damage. The heat generation and transfer mechanisms during the cutting were involved. The CFRP were treated as an equivalent homogeneous material, with the damage initiation criteria and damage evolution laws defined. The degradation equations of the mechanical properties with temperature variation were formulated during the material modelling. Based on this numerical model, the predicted material removal process, cutting force, and machining temperature showed good agreement with experimental results in a validated thermal range of 303–315 K. Then, the effects of the tool geometries and processing parameters on both the temperature distribution and subsurface damage depth were assessed. It was concluded that when the rake angle is positive, higher maximum temperature near the cutting edge (MT), smaller cutting forces and larger subsurface damage depths are produced under greater rake angles. The contact area and friction between the workpiece and the tool rake face are larger under greater cutting depth, resulting in an upward trend in workpiece temperature, and the cutting force and subsurface damage depth also increase with increasing depth of cut. At lower cutting speeds, smaller MTs and larger heat-affected zones are obtained, and the reduced cutting forces and subsurface damage depths are acquired under high cutting speeds.