A new and comprehensive characterisation of tool wear in CFRP drilling using micro-geometry and topography studies on the cutting edge

Raj, D. Samuel; Karunamoorthy, L.

doi:10.1016/j.jmapro.2018.04.014

Cited by 37 publications

(17 citation statements)

References 22 publications

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“…Once impacted over the tool, the dragged material causes its own removal in the direction of evacuation, which may develop longitudinal traces that accumulate tensile stresses. These reduce the tool resistance to compression and may cause its premature failure [ 11 , 12 , 13 ].…”

Section: Introductionmentioning

confidence: 99%

Tool Wear Mechanism in Cutting of Stack CFRP/UNS A97075

et al. 2018

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The aeronautics industry’s competitiveness has led to the need to increase productivity with one shot drilling (OSD) systems capable of drilling stacks of dissimilar materials (fibre/metal laminates, FML) in order to reduce riveting times. Among the materials that constitute the current aeronautical models, composite materials and aluminium (Al) and titanium (Ti) alloys stand out. These one-pass machining techniques produce high-quality holes, especially when all the elements that have to be joined are made of the same material. This work has followed a conventional OSD strategy and the same cutting conditions applied to CFRP (carbo-fibre-reinforced polymer), Al and CFRP/Al stacked sheets to know the wear mechanisms produced. With this purpose, results were obtained by using current specific techniques, such as microstructural analysis, monitoring of the shear forces and analysis of macrogeometric deviations. It has been determined that when these drilling techniques are applied under the same cutting conditions to stacks of materials of a different nature, the results of the wear mechanisms acting on the tool differ from those obtained when machining each material separately. This article presents a comparison between the effects of tool wear during dry drilling of CFRP and UNS A97075 plates separately and when machined as stacks.

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Section: Introductionmentioning

confidence: 99%

Tool Wear Mechanism in Cutting of Stack CFRP/UNS A97075

et al. 2018

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“…As mentioned by other authors [2,3,4,5,6,7,8,9], when drilling CFRP-only, the drill wear is mainly of the abrasive type (Figure 12). The cutting edge radius increases leading to edge rounding wear.…”

Section: Tool Wear In Cfrp Ti6al4v and Cfrp/ti6al4v Stacksmentioning

confidence: 63%

“…Drill wear is measured using a KEYENCE VHX-1000E digital microscope which allows a 2D profile of the cutting edge to be obtained by the changes of texture of the picture recorded (Depth from Defocus). These measurements are performed perpendicularly to the two main edges and at three points: 200 μm from the tip of the tool, in the center of the cutting edge (1200 μm from the tip) and at 200 μm from the junction between the main edge and the central edge [5,6]. These profiles are used to rebuild the 3D geometry of the cutting edge using CAD software (Figure 5).…”

Section: Methodsmentioning

confidence: 99%

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Wear Mechanisms and Wear Model of Carbide Tools during Dry Drilling of CFRP/TiAl6V4 Stacks

et al. 2019

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The present contribution on tool wear during the drilling of carbon fiber composite materials (CFRP)/Ti stacks intends to determine (i) if the adhesion of titanium to carbide is mechanical or chemical, (ii) the possible diffusion path, (iii) if the titanium is the only element involved in the adhesion and (iv) the role of the CFRP in this wear. The overall tool wear is not the sum of the wear in each material and there is a multiplicative effect between them. It has been pointed out that the maximum temperature reached during drilling is higher than 180 °C, 400 °C and 750 °C respectively in the CFRP and Ti plates alone and in the Ti part of the stack. As tungsten carbide CW is not in equilibrium with titanium above 250 °C, the diffusion path is CW/(Ti,W)C/Ti as confirmed by Auger analysis. For temperatures above 500 °C, (Ti,W)C becomes very sensitive to oxidation allowing a friable oxycarbide (Ti,C,O) to form, which explains the erosion of the tool. The CW is therefore the weakest link in the drilling of CFRP/Ti stacks. Improving the performance of the tool involves the use of a coating, the development of a tool material having low chemical affinity with Ti and/or the use of cryogenic lubricant.

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“…The material properties of NRF are different than the material properties of the matrix material (epoxy resin) and of the reinforcing fibers (carbon), the machinability of these NRF is therefore different too. Special cutting tools for CFRP machining are usually (i) good in wear resistance against carbon fibers [53][54][55][56][57][58], (ii) excellent in minimizing delamination [59][60][61][62], furthermore, (iii) they are good in reducing the number of uncut reinforcing fibers [63][64][65][66]. Nevertheless, these special cutting tools usually do not cut properly NRF.…”

Section: Results Of Drilling Experimentsmentioning

confidence: 99%

Analysis of Characteristics of Surface Roughness of Machined CFRP Composites

Geier

Pereszlai

2019

Period. Polytech. Mech. Eng.

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Measuring and characterizing of surface roughness of machined surfaces of carbon fiber reinforced polymer (CFRP) composites are difficult due to the occurrence of special surface damages (delamination, uncut fibers, fiber pull-outs or micro-cracks, etc.). The main objective of the present study is to analyze the characteristics of surface roughness of machined unidirectional CFRP in detail. Numerous conventional drilling, helical milling, and edge trimming experiments were carried out with different cutting tools in order to analyze the influence of them on the average surface roughness (Ra), on the roughness depth (Rz) and on the Rz /Ra parameter. The surface roughness was measured by a Mitutoyo SJ-400 contact profilometer and an Alicona Infinite Focus confocal microscope. The usability of the contact profilometer was experimentally tested and compared its results with the results of the confocal microscope. Experimental results show that the contact profilometer is suitable for measuring surface roughness of CFRP, furthermore, values of Rz /Ra of drilled and edge trimmed surfaces of unidirectional CFRP are changing in a wide interval: from 5 to 14 μm/μm due to the special surface damages. Based on this research, the machinability analysis of CFRP is suggested to be extended to the analysis of the Rz /Ra parameter.

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A new and comprehensive characterisation of tool wear in CFRP drilling using micro-geometry and topography studies on the cutting edge

Cited by 37 publications

References 22 publications

Tool Wear Mechanism in Cutting of Stack CFRP/UNS A97075

Tool Wear Mechanism in Cutting of Stack CFRP/UNS A97075

Wear Mechanisms and Wear Model of Carbide Tools during Dry Drilling of CFRP/TiAl6V4 Stacks

Analysis of Characteristics of Surface Roughness of Machined CFRP Composites

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