Finite Element Simulation of Delamination Processes when Side Milling the Edges of Cross-Ply Carbon Fiber Reinforced Polymer (CFRP) Boards

The machining of advanced composite materials is essential in several engineering applications. However, machining operations can induce delamination or other defects especially on fiber reinforced composite materials. In order to understand relationships between delamination and milling processes, FE-simulations of side milling operations for cross-ply carbon fiber reinforced polymers (CFRP) have been designed with the use of the LS-PrePost and calculated with the explicit LS-DYNA solver. The obtained results have shown promising results in the simulation of milling operations with realistic cutting tool geometries, operation parameters and equivalent homogenous material models of CFRP. With the use of experimental milling tests and samples presenting delamination, some simulation models have been optimized. A reciprocal learning process between experiment and simulation has taken place in which significant process, material and simulation parameters inducing delamination on the work piece have been identified for future work in the field of machining CFRP.