Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures ix
List Abbreviations, Symbols and Nomenclature xi
CHAPTER 1 : INTRODUCTION 1
1.1 Overview
1 1.2
Problem Statement 3
1.3 Objectives
4 1.4
Scope of Work 4
1.5 Chapters Organization
5
CHAPTER 2 : LITERATURE REVIEW 6
2.1 Background
6 2.2
Previous Research Work on Composite Machining 8
2.3 Composite Materials
10 2.3.1
Carbon Fiber Reinforced Plastic CFRP 11
2.3.2 Manufacture Process of CFRP
12 2.3.3
Aluminum Alloy AL2024 12
2.4 Machining Simulation Using Engineering Simulation Software
13 2.4.1
Machining Simulation 16
2.4.2 Engineering Simulation Software
16 2.4.3
Finite Element Simulation of Machining Process 17
2.4.4 Process Simulation Approach
18 2.4.5
Mesh Adaptivity 19
TABLE OF CONTENT
v
2.4.6 ABAQUSCAE software
20 2.4.7
ABAQUSEXPLICIT 21
2.4.8 VERICUT Simulation software
21 2.5
Chapter Summary 22
CHAPTER 3 : METHODOLOGY 23
3.1 Project Planning
23 3.2
Process Planning Using ABAQUS 26
3.3 Stages in ABAQUSCAE Analysis
28 3.3.1
Pre-processing ABAQUSCAE 28
3.3.2 Simulation ABAQUS EXPLICIT
29 3.3.3
Post processing ABAQUS CAE 29
3.4 Composites Modeler for ABAQUS Using SIMULAYT Add-On
30 3.4.1
Composite Modeler with SIMULAYT Composite Modeler 31
3.4.2 Methods to Create Composite Modeler with SIMULAYT
33 3.5
Finite Element Modelling FEM for CFRPAL2024 34
3.5.1 3D Finite Element Modelling FEM
34 3.5.2
Orthogonal Finite Element Modelling FEM 35
3.5.3 Material Properties and Material Constitutive
36 3.5.4
Material Damage Criteria 38
3.5.5 Contact Model Analysis
38 3.6
Process Planning Using VERICUT 39
3.6.1 Development of the Simulation Environment in VERICUT
41 3.6.2
3D Model in SOLIDWORKS Static Models 41
3.6.3 Simulation of Tool Path Using VERICUT
42 3.7
Chapter Summary 43
CHAPTER 4 : RESULT DISCUSSION 44
4.1 Data Grouping
44 4.2
Design and Modelling of Parts 45
4.3 Defining the Material’s Properties in ABAQUS
49 4.4
Composites Modeler Draping Simulations and Solid Extrusion 50
4.5 Assembly Meshing in ABAQUS
54
vi
4.6 Process of Simulation in 3D Finite Element Modelling FEMs
55 4.7
XY Data Graph 62
4.8 Construction Of The Virtual Machine in VERICUT
63 4.9
Design and Modeling The Machine 64
4.10 Process Simulation of Tool Path in VERICUT 66
4.11 Chapter Summary 68
CHAPTER 5 : CONCLUSION FUTURE WORK 69
