Laboratory for Manufacturing and Sustainability

Multilayer structural members are used extensively in aerospace applications and there is a critical need for accurately modeling their machining, especially drilling. Modeling the machining of multilayer materials is complex as it’s a 3D dynamic process with multiple interacting material domains. These models can be used to minimize edge imprecisions and increase workpiece accuracy in machining by optimizing the process and geometric parameters. This report discusses the challenges in modeling the machining of aerospace multilayered materials, which include metal-metal stackups and metal-composite stackups. The challenges composite materials specifically pose from a modeling perspective are also discussed. A brief review of existing work in composite machining and finite element modeling is also presented. Finally, a framework for solving this problem is suggested and a roadmap based on the framework is presented.