Dynamic Force Model Based on Material Removal Behavior Affected by Grinding Mode in <scp>CF</scp> / <scp>PEEK</scp> Grinding

ABSTRACT Carbon fiber‐reinforced poly‐ether‐ether‐ketone (CF/PEEK), representing a category of carbon fiber reinforced thermoplastics (CFRTP), is gaining traction in industries such as aerospace, aviation, energy, and medicine. Grinding is usually employed to enhance the surface finish and dimensional precision of CF/PEEK composites. Previous studies have overlooked the impact of grinding modes on material removal mechanisms and the distribution of dynamic grinding forces. Furthermore, as the representative difficult‐to‐process material, the grinding behavior of CF/PEEK is so complicated that it brings challenges for grinding force modeling. To quantitatively analyze the grinding force characteristics under different grinding modes including up‐grinding and down‐grinding, a dynamic force model in CF/PEEK composites grinding was established on the basis of the removal mechanism. The theory of elastic foundation beam and stress failure criterion was adopted to establish the deflection and mechanical model of single fiber. Then, the Poisson disk sampling algorithm was used to simulate the fiber distribution. Further, considering fiber‐resin contact states and random grit distribution, the dynamic grinding force model was proposed and experimentally verified. The average prediction error was less than 13%. This research could provide better insight into the grinding force characteristics of CF/PEEK.