2D and 3D Finite Element models for the edge trimming of CFRP

2D and 3D finite element models were developed to simulate the machining of CFRP with different levels of tool wear. Models were validated by edge trimming experiments on a uni-directional laminate at different fibre orientations using a three flute PCD milling tool. MSC Marc was used to develop the model and in conjunction with a Hashin damage material model. Modelling results are validated according to measured cutting forces at different cutting speeds and feed rates. A percentage difference of +10% and +5% was calculated for the 3D model for Fx and Fy respectively, while a percentage difference of -9% and -50% was found for the 2D model. Tool wear was found to have a significant effect on measured cutting forces.