Understanding Chip Formation in Orthogonal Cutting of Aeronautical Thermoplastic CF/PEKK Composites Based on Finite Element Method

There has been an enormous increase in using of carbon fiber reinforced thermoplastic (CFRTP) especially reinforce polyetherketoneketone (CF/PEKK) automotive and aeronautical industries. However, fundamental material removal mechanism such never elucidated the literature. In this work, finite-element (FE) method is deployed microscale numerical model considering fiber, matrix interface established to understand mechanisms chip formation orthogonal cutting unidirectional (UD) CF/PEKK composites. Chip subsequent surface / subsurface damage with different orientations (0°, 45°, 90°, 135°) are modelled compared. Results suggest that, for CF/PEKK, significantly affected by orientation most severe can be seen at 135°, as a result bending fracture below ideal machined surface.