Development of a Novel Friction Model for Machining Simulations in Unidirectional Composite Materials.

Area of Science:

• Materials Science and Engineering
• Mechanical Engineering
• Tribology

Background:

• Current finite element (FE) machining simulations for carbon fibre-reinforced polymers (CFRPS) rely on constant coefficients of friction (COFs).
• These constant COFs are derived from closed-loop tribology experiments, which do not accurately represent actual machining conditions.

Purpose of the Study:

• To develop a novel experimental open-loop tribological testing method for CFRP machining.
• To create a dynamic FE friction model that accounts for fibre angle, contact pressure, and slip rate.
• To enhance the accuracy of FE machining simulations for CFRPs.

Main Methods:

• Implementation of a novel open-loop tribological testing methodology.
• Development of a dynamic friction model based on fibre angle, contact pressure, and slip rate.
• Validation of the dynamic model against experimental data and traditional constant COF FE simulations.

Main Results:

• The proposed dynamic friction model significantly improves the accuracy of open-loop tribological simulations.
• The model provides a more realistic representation of friction under CFRP machining conditions compared to constant COFs.
• Successful validation against experimental results and existing FE simulations.

Conclusions:

• The novel open-loop tribological testing method and dynamic friction model offer a significant advancement for CFRP machining simulations.
• This approach bridges the gap between tribology, machining, and FE simulation, leading to higher fidelity predictions.
• The validated dynamic model provides confidence for future implementation in complex CFRP machining simulations.