Static Finite Element Modeling of Milling in Flexible Composite Plates

This study presents a static finite element analysis of the milling of a flexible unidirectional glass fiber–reinforced polymer (UD-GFRP) plate. The workpiece is modeled as a clamped–free cantilever, with cutting forces evaluated independently of structural deflections and applied along the machined edge. SC8R continuum shell elements are employed to accurately represent through-thickness loading and bending behavior. A mesh sensitivity analysis is conducted to determine a suitable discretization, leading to a 64 × 56 × 8 element mesh. For the investigated configuration (, mm/tooth), the out-of-plane displacement reaches approximately 120 µm near the free end of the plate, whereas in-plane displacements reach up to-75 µm. These in-plane displacements are greater than or equal to the nominal feed per tooth, indicating a highly significant influence on chip formation. This work provides a basis for understanding the structural response of flexible composite plates during trimming and emphasizes the need for coupled force–deformation formulations.