考虑孔隙缺陷的CFRP微观切削仿真与实验研究  

Simulation and experimental study of CFRP micro cutting considering voids defects

作　　者：李树健[1] 周永超 陈蓉[2] 李常平 邱新义[1] 李鹏南[1] LI Shujian;ZHOU Yongchao;CHEN Rong;LI Changping;QIU Xinyi;LI Pengnan(School of Mechanical Engineering,Hunan University of Science and Technology,Xiangtan 411201,China;School of Mechanical Engineering,Hunan Institute of Engineering,Xiangtan 411104,China)

机构地区：[1]湖南科技大学机电工程学院,湘潭411201 [2]湖南工程学院机械工程学院,湘潭411104

出　　处：《复合材料学报》2023年第1期625-636,共12页Acta Materiae Compositae Sinica

基　　金：国家自然科学基金(51975208,51775184,51805163)。

摘　　要：碳纤维增强树脂基复合材料(CFRP)在航空航天等领域应用广泛。在CFRP制造过程中难以避免会产生孔隙等缺陷,对后续的切削加工造成一定影响。在考虑了CFRP成型过程形成的孔隙缺陷基础上,运用有限元仿真模拟方法,从纤维-树脂-界面尺度建立了含孔隙缺陷的CFRP微观切削仿真模型,研究了不同孔隙率条件下不同纤维排布方向的CFRP微观切削行为,并通过实验验证了仿真模型的正确性。研究结果表明:孔隙的存在会增加刀具的“空切”现象,从而对CFRP切削过程的切削力、材料破坏及亚表面损伤、材料能量等产生影响。随孔隙率的增加,切削力呈下降趋势,孔隙边缘的纤维产生整体断裂的倾向增加;孔隙对0°、45°和135°纤维排布方向的CFRP切削加工的面下损伤影响不大,在纤维排布方向为90°条件下,孔隙率高于3vol%时对加工表面的面下损伤具有较大影响;在材料内部能量耗散方面,“顺切”(纤维方向角小于90°)时的总耗散能低于“逆切”,随孔隙率增加,总耗散能降低。Carbon fiber-reinforced plastic(CFRP)composites have been widely used in aerospace and other most advanced fields.It is difficult to avoid voids and other defects in the manufacturing process of CFRP,which will have a certain impact on the subsequent machining.Based on the consideration of the voids defects in the process of CFRP forming,a CFRP micro cutting simulation model with void defects was established from the fiber-resin-interface scale by using the finite element simulation method.The micro cutting behavior of CFRP with different fiber orientations under different void content conditions was studied,and the correctness of the simulation model was verified by experiments.The results show that the existence of voids will increase the‘virtual cutting’phenomenon of the tool,which will have an impact on the cutting force,material damage,sub-surface damage and material energy in the cutting process of CFRP.The cutting force decreases with the increase of void content,and the tendency of fibers at the edge of voids to produce overall fracture will increase.The voids have little effect on the damage under the machined surface of CFRP with 0°,45°and 135°fiber orientations.The void content higher than 3vol%has a great effect on the damage under the machined surface when the fiber orientation is 90°.In terms of energy dissipation inside the material,the total dissipated energy in‘forward cut’(fiber orientation angle less than 90°)is lower than‘reverse cut’,furthermore,the total dissipated energy decreases with the increase of void content.

关 键 词：CFRP 孔隙 切削 材料损伤 有限元仿真 

分 类 号：TQ327.3[化学工程—合成树脂塑料工业]