Modeling of machining of composite materials: A review

This paper provides a comprehensive review of literature, mostly of the last 10–15 years, on modeling of machining of composite materials with a focus on the process of turning. The paper discusses modeling of both fiber reinforced and particle reinforced composites. Modeling studies include molecular dynamic simulations, 2-D and 3-D finite element models and the emerging field of multi-scale models. In fiber reinforced composites the focus is on glass and carbon fiber reinforced polymeric composites as well as long fiber reinforced metal matrix composites. On the other hand modeling of particulate composites is restricted to that of metal matrix composites (MMC). The paper includes recent modeling work to predict cutting forces, tool–particle interaction, cutting temperatures and machined sub-surface damage. A case study on the machining of the MMC A359 aluminum matrix composite reinforced with 20% by volume fraction silicon carbide particles is included to showcase the hierarchical multi-scale machining model.

► A comprehensive review of modeling approaches on machining of composites is given.
► New emerging multiscale modeling methods for composite materials are presented.
► A case study on multiscale modeling on machining of MMC is presented.