Damage-incorporated four-step mean-field method for simulating CFRP machining: a novel algorithmic approach

This paper introduces a theoretical and numerical framework for simulating the machining of carbon fiber-reinforced plastics (CFRP). Initially, the limitations of conventional mean-field methods (MFM) are analytically demonstrated through theoretical considerations. Subsequently, constitutive models that account for both temperature and rate dependencies are developed for the individual components of CFRP, namely the fiber, interface, and matrix. The paper then systematically elaborates on the proposed four-step mean-field framework, which integrates micromechanical principles with failure criteria. To calibrate the material parameters, tensile and compression tests are conducted on the individual constituents, and the experimental data are utilized to fit the model. Finally, CFRP milling experiments and simulations are carried out to validate the proposed method, with the simulation results showing strong agreement with empirical observations.