Numerical simulation of chip formation during edge cutting machining of 3D orthogonal woven fiber- reinforced composite workpiece. Part 1: a review and models of materials

Edge cutting machining is more commonly used to produce precise parts made of fiber-reinforced composite (FRC) with three-dimensional woven orthogonal structure. The disadvantage of this machining method is increased hairiness of the machined surface, fiber-matrix debonding, peeling and chipping. One possible solution to minimize this disadvantage is to use rational tool parameters and rational tool wedge motion in relation to the axes of the fibers. Such motion can be identified using numerical computer micro modeling of the chip formation process. The difficulty of such modeling it the need to have available both a geometric model of the composite itself and models of composite components, including a model of matrix-fiber boundary layer. Modeling based on the method of smoothed particle hydrodynamics - Smooth Particle Hydrodynamics (SPH) is the most promising type of machining process micro modeling. Currently, no publications, which present SPH micro models of three-dimensional woven composites with the description of matrix-fiber boundary layers, have been found. It was also not possible to find specific models for the matrix-fiber boundary layers. In order to solve the problem of rational machining of FRC workpieces using edge cutting tools, an analysis of published material models and parameters of such models was carried out. These models should be subsequently used for SPH modeling of the machining process. The analysis made it possible to select the required material models and their parameters for fiber and matrix materials of a metal composite. The analysis of the graphical relationships obtained from the publications, made it possible to select the parameters for the fiber-matrix boundary layer model. This selection is based on the hypothesis that the boundary layer should be described by the same model, that is used for the matrix itself, but with parameters that determine lower failure stresses. The obtained solutions are planned to be used to simulate machining process of a workpiece made of three-dimensional woven FRC in the second part of the presented research.