Three-dimensional Multi-scale Modeling and Drilling Process Technology of Carbon Fiber Reinforced Polymer Composites

doi:10.3901/JME.2025.07.144

Abstract

Abstract: Carbon fibre reinforced polymer (CFRP) composites are widely used in aerospace, aviation, transportation, and civil industries due to their excellent mechanical properties and lightweight characteristics. However, the layered structure and anisotropic nature of CFRP lead to defects such as delamination, burrs, and tearing during drilling, which severely affect joint quality and structural integrity. This study developed an innovative multi-scale machining modelling method that integrates macroscopic, mesoscopic, and microscopic material models into a unified finite element simulation framework. The mechanical behaviour and defect formation mechanisms of CFRP during the drilling process are systematically investigated using Abaqus/Explicit software to simulate the drilling process of CFRP laminates in detail, revealing the stress distribution and damage evolution under different fibre orientations. The simulation results show that at a 0° fibre orientation, the drilling stress is concentrated in the cutting zone, resulting in minor damage and relatively smooth surfaces. Conversely, at a 90° fibre orientation, the stress propagated along the fibres, causing severe delamination and fibre pull-out, leading to rough and irregular surfaces. These findings are validated through scanning electron microscope (SEM) observations and surface roughness measurements, with experimental results showing high consistency with the simulation data. Further analysis indicated that optimizing drilling parameters and fibre orientation could significantly reduce machining defects and improve the surface quality of CFRP holes. This study not only provides a theoretical basis for understanding the stress distribution and damage evolution in CFRP drilling but also offers practical guidance for optimizing CFRP machining processes. The application of the multi-scale modelling method allows effective prediction and control of defects during machining, enhancing the machining quality and service life of CFRP structural components.

Key words: multi-scale modeling, carbon fiber reinforced polymer (CFRP), finite element simulation, drilling process, damage mechanism

CLC Number:

TG156

FU Guoyu, LI Hao, WU Weizhou, LI Shipeng, ZHAO Qing, QIN Xuda. Three-dimensional Multi-scale Modeling and Drilling Process Technology of Carbon Fiber Reinforced Polymer Composites[J]. Journal of Mechanical Engineering, 2025, 61(7): 144-155.

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