This paper presents a novel model for simulation of polymer-matrix composites (PMCs). The model is
developed for orthogonal cutting configuration and finite element analysis (FEA). For enhancing chip formation
simulation, adaptive mesh technique and dynamic explicit elements are used. The assumption of
equivalent homogeneous material (EHM) is considered for modelling the composite plate. The model
assumes plane stress state and orthotropic behaviour. The failure mechanism is modelled by the Tsai-Hill
criterion. Comparison between the current results and experimental findings yields better agreement
than the numerical model proposed in literature by Nayak et al. [Nayak D, Bhatnagar N, Mahajan P.
Machining studies of UD-FRP composites. Part 1: Effect of geometrical and process parameters. Mach
Sci Technol 2005;9(4):481–501]. The failure envelopes have served to examine the damage generated
in the sub-surface, below the trim plane. Sensitivity of chip formation mechanism and damage generation
on the fibre orientation is confirmed. The current model showed real enhancement over the model proposed
by Nayak et al.