Modeling Tools for the Drilling of Polymer Matrix Composites (PMCs)

Global Engineering and Materials, Inc. (GEM) along with its team member, National Institute for Aviation Research (NIAR) at Wichita State University, propose to develop a micro-macro coupling tool for simulation of thermal-mechanical response and multi-mode failure progression in selected polymer matrix composites under drilling. A rational approach based on a micro-scale model is developed to characterize the composite properties based on the temperature dependent matrix, fiber, and interface properties. A digital material model will be formed based on a surrogate model using simulation results of the micro-scale model. A user-defined material model (VUMAT) will be developed for a thermal mechanical response and failure prediction at macro-scale level via the general-purpose finite element software Abaqus/explicit to simulate the material removal process resulting from intra- and inter-ply damage. Additionally, an advanced drilling system with programmable setting parameters will be used to demonstrate the capability of using sensor data and model predictions for the knowledge informed drilling. NDI techniques including X-ray CT will be applied to determine the location and size of damage areas of drilled specimens for tool validation study. Capability demonstration of the developed modeling tool will be performed for coupons using multiple materials and hole configurations.