Three-dimensional finite element modeling of drilling CFRP composites using Abaqus/CAE: a review

The extra-ordinary properties of carbon fiber reinforced polymer (CFRP) composites and its outstanding performance in their structural applications, especially in aerospace industry where high strength to weight ratio is highly desirable, have given them a steadfast attention in the engineering materials research world. Drilling of CFRP materials to facilitate holes for component assembly subjects them to various modes of failure due to their anisotropy and in homogeneity. A requisite means of investigation and analysis is therefore required in order to understand these failure modes. Traditionally, the failure modes have been studied through experiments and more recently numerical simulations. There are dozens of finite element (FE) software available for numerical simulation with Abaqus/CAE being the mostly used for composites analysis. The numerical setup is a complicated process requiring some level of expertise in order to get accurate results which can be validated with experimental results. Upcoming researchers find it difficult, and they end up spending much time preparing for a successful simulation due to scattered information in scientific literature about modeling. This article tries to make work easier for new researchers by doing a review of 3D modeling of drilling CFRP using Abaqus/CAE software. The article features models from highly experienced researchers and their validated results with step-by-step setup guidelines. The objective is to provide a basic guideline to new researchers on the appropriate material properties and damage models for a successful and accurate simulation.