Oblique Cutting Configuration for Modeling Thermal Behavior During Drilling GFRP/Al Stack Composites

This study examines the crucial impact of temperature on the composite stack interface during the machining of composites with varying stacking sequences. The investigation of temperature history informs about the heat partition and helps for managing cutting parameters, which is essential for optimizing process efficiency. A damage coupled approach is developed using ABAQUS/Explicit code for simulating the drilling process of GFRP/Al stacks. The model is based on oblique cutting configuration (OCC). Specially, it incorporates a user-defined material subroutine to account for progressive failure mechanisms and temperature-dependent properties. The model incorporates a strong temperature-to-stress dependency to improve simulation accuracy. The model predicts temperature histories generated during the cutting process, at the interface of both stacking arrangement, GFRP/Al and Al/GFRP. It also analyzes the impact of cutting speed on both thermal and mechanical responses. The results highlight the thermal behavior at the stack interface, offering valuable insights for optimizing machining operation. This approach aims to improve machining performance and extend the durability of GFRP/Al components, providing a reliable framework for addressing challenges in hybrid material machining. Chip formation in the two studied arrangements is discussed through the inclination angle, describing the phase to be attacked first.