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Static Finite Element Modeling of Milling in Flexible Composite Plates

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Abstract:

This study presents a static finite element analysis of the milling of a flexible unidirectional glass fiber–reinforced polymer (UD-GFRP) plate. The workpiece is modeled as a clamped–free cantilever, with cutting forces evaluated independently of structural deflections and applied along the machined edge. SC8R continuum shell elements are employed to accurately represent through-thickness loading and bending behavior. A mesh sensitivity analysis is conducted to determine a suitable discretization, leading to a 64 × 56 × 8 element mesh. For the investigated configuration (, mm/tooth), the out-of-plane displacement reaches approximately 120 µm near the free end of the plate, whereas in-plane displacements reach up to-75 µm. These in-plane displacements are greater than or equal to the nominal feed per tooth, indicating a highly significant influence on chip formation. This work provides a basis for understanding the structural response of flexible composite plates during trimming and emphasizes the need for coupled force–deformation formulations.

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Periodical:

Defect and Diffusion Forum (Volume 450)

Pages:

93-102

DOI:

https://doi.org/10.4028/p-2lx7wD

Citation:

Cite this paper

Online since:

April 2026

Authors:

Matthias Nutte*, Edouard Rivière-Lorphèvre, Valentin Dambly, Pedro José Arrazola, Ismail Lazoglu, Aurélie Granjon, François Ducobu

Keywords:

Composite Materials, Flexible Parts, Machining, Milling, Trimming Operation

Funder:

The publication of this article was funded by the Mondragon Goi Eskola Politeknikoa, J.M.A. S.Coop

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* - Corresponding Author

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