A comparative study of hole-making performance by coated and uncoated WC/Co cutters in helical milling of Ti/CFRP stacks

Li, Shipeng; Qin, Xuda; Jin, Yan; Sun, Dan; Li, Yonghang

doi:10.1007/s00170-017-0842-8

Cited by 32 publications

(7 citation statements)

References 40 publications

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“…For the holes made with tool T1, the difference of Ra values between hole number 60 and number 1 is 2.96 µm, whereas for the holes made with tool T2, the difference of Ra values between hole number 60 and number 1 is 4.62 µm. As identical cutting conditions were employed with both tools, the Ra difference can be related to the different wear level of the tool cutting-edge [ 28 , 29 ].…”

Section: Resultsmentioning

confidence: 99%

Characterization of a New Dry Drill-Milling Process of Carbon Fibre Reinforced Polymer Laminates

2018

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Carbon Fibre Reinforced Polymer (CFRP) composites are widely used in aerospace applications that require severe quality parameters. To simplify the assembly operations and reduce the associated costs, the current trend in industry is to optimize the drilling processes. However, the machining of CFRP composites is very challenging compared with metals, and several defect types can be generated by drilling. The emerging process of orbital drilling can greatly reduce the defects associated with the traditional drilling of CFRP, but it is a more complex process requiring careful process parameters selection and it does not allow for the complete elimination of the thrust force responsible for delamination damage. As an alternative to traditional and orbital drilling, this work presents a new hole making process, where the hole is realized by a combination of drilling and peripheral milling performed using the same cutting tool following a novel tool path strategy. An original tool design principle is proposed to realize a new drill-milling tool, made of a first drilling and a subsequent milling portion. Two different tool configurations are experimentally tested to evaluate the performance of the newly-conceived combined drill-milling process. This process is quick and easy, and the experimental results show an improvement in the drilled hole quality.

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Section: Resultsmentioning

confidence: 99%

Characterization of a New Dry Drill-Milling Process of Carbon Fibre Reinforced Polymer Laminates

2018

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“…The hole diameter values were closer to the nominal diameter with the T1 uncoated cutting tool compared to the coated tools because T1 had a sharper cutting edge than the other two [40]. Li et al reported that, in the drilling CFRP, the uncoated tool performed closer to the nominal diameter value compared to multilayered TiAlN+AlCrN-and TiN-coated tools and that this did not change with the increasing number of holes [41]. Similarly, Kim et al reported a higher mean diameter value with coated drills compared to uncoated drills [42].…”

Section: Evaluation Of Dimensional Accuracymentioning

confidence: 90%

An experimental study on hole quality and different delamination approaches in the drilling of CARALL, a new FML composite

Eki̇ci̇¹,

Motorcu²,

Yıldırım³

2021

FME Transactions

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In this study, the hole quality was investigated in the drilling of CARALL composite. In addition, the delamination factor calculation approaches of Chen, Davim, and Machado were compared in terms of the delamination damage at the hole entrance surface. Chen's approach is based on the conventional delamination factor (F d) and Davim's on the adjusted delamination factor (F da). Finally, Machado's approach is based on the minimum delamination factor (F min). The values closest to the nominal hole diameter value were obtained with the uncoated (T1), followed by the TiN-TiAlN-coated (T2) and TiAl/TiAlSiMoCr-coated (T3) carbide drills, respectively. The average circularity error values for the hole top and bottom surfaces were 6.184 µm, 7.647 µm, and 8.959 µm for T1, T2, and T3 tools, respectively. Delamination factor values varied between 1.174 and 1.804. The F da values were found to be the highest, followed by F d values, with F dmin values determined as the lowest.

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“…The first one is that the cutting speed of the drilling center is zero, which may lead to adverse situations like dimensional deviation and tool deflection of holes drilled through larger thrust cutting force [1]. The second problem is the formation of exit burrs in the holes as a result of plastic deformation of workpiece materials and the geometry of cutting tool [2]. As an emerging holemaking technology, helical milling can achieve high accuracy and quality which has been extensively used to manufacture parts in aerospace industry.…”

Section: Introductionmentioning

confidence: 99%

Investigation on cutting performance in ultrasonic assisted helical milling of Ti6Al4V alloy by various parameters and cooling strategies

Zou

Guo

et al. 2023

Int J Adv Manuf Technol

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Ti6Al4V alloy is the typical difficult-to-machine materials and often result in rapid tool wear, leading to poor machining quality in aircraft assembling. Compared to conventional helical milling, the ultrasonic assistant helical milling (UAHM) process has indicated its superior performance, however it is still a great challenge to improve the hole surface quality and accuracy. In addition, few studies has been conducted on the effect of different variables and cooling strategies on the hole-making performance in longitudinal-torsional ultrasonic assisted helical milling (LT-UAHM). This work mainly aims to investigate the surface finish and accuracy of the holes machined in LT-UAHM of Ti6Al4V alloy. The design approach of Taguchi experiment was employed to study how major variables such as the cutting speed, tangential feed, axial feed and the workpiece hardness influence the dimensional and geometrical tolerances and surface roughness. This paper also discussed the effect of three cooling strategies, i.e. dry condition, air coolant and minimum quantity lubrication (MQL) in LT-UAHM. Theoretical analysis demonstrated that the MQL coolant can be nebulized into hyper-fine droplets owing to the resonant cavitation phenomenon. Combined with the penetrating action caused by the separate-cutting principles of LT-UAHM, the cooling and lubrication performance of MQL was further enhanced. As a result, MQL<-UAHM had the most positive effect on circularity, cylindricity, nominal diameter and surface roughness, contributing to 34%, 32%, 39% and 40%, respectively. The second important machining factor was the cutting speed, contributing to 31%, 29%, 36% and 22%, respectively. The tangential feed and workpiece hardness have the negative effect on geometrical accuracy, respectively.

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A comparative study of hole-making performance by coated and uncoated WC/Co cutters in helical milling of Ti/CFRP stacks

Cited by 32 publications

References 40 publications

Characterization of a New Dry Drill-Milling Process of Carbon Fibre Reinforced Polymer Laminates

Characterization of a New Dry Drill-Milling Process of Carbon Fibre Reinforced Polymer Laminates

An experimental study on hole quality and different delamination approaches in the drilling of CARALL, a new FML composite

Investigation on cutting performance in ultrasonic assisted helical milling of Ti6Al4V alloy by various parameters and cooling strategies

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