A 3D progressive material damage model for Fe simulation of machining a unidirectional FRP composite

In existing finite element (FE) models of machining a unidirectional fiber-reinforced polymer composite (FRP), the instantaneous damage strategy or two-dimensional (2D) progressive damage models are most widely used. In this study, an energy-based three-dimensional progressive damage model was proposed for damage evolution and continuous stiffness degradation of FRP material. Maximum stress criterion was applied for damage initiation prediction. The progressive damage model was implemented in Abaqus user subroutine and incorporated into a macromechanical FE model. The simulated chip shapes and cutting forces were compared with those obtained in experiment and in existing 2D models when applicable. The result is consistent with the existing simulation work in the literature, while with a better agreement as of the cutting forces trends prediction.