Orthogonal Cutting Modeling of Hybrid CFRP/Ti toward Specific Cutting Energy and Induced Damage Analyses

This paper studied the machinability of hybrid CFRP/Ti stack via the numerical approach. To this aim, an original FE model consisting of three fundamental physical constituents, i.e., CFRP phase, interface and Ti phase, was established in the Abaqus Explicit/code to construct the machining behavior of the composite-to-metal alliance. The CFRP phase was modeled as an equivalent homogeneous material (EHM) by considering its anisotropic behavior relative to the fiber orientation (theta) while the Ti alloy phase was assumed to exhibit isotropic and elastic-plastic behavior. The "interface" linking the "CFRP-to-Ti" contact boundary was physically modeled as an intermediate transition region through the concept of cohesive zone (CZ). Different constitutive laws and damage criteria were implemented to simulate the chip separation process of the bi-material system. The key cutting responses including specific cutting energy consumption, induced subsurface damage, and interface delamination were precisely addressed via the comprehensive FE analyses, and several key conclusions were drawn from this study.