An investigation of drilling high-strength CFRP composites using specialized drills

Xu, Jinyang; Li, Chao; Chen, Ming; Mansori, Mohamed El; Ren, Fei

doi:10.1007/s00170-019-03753-8

Cited by 82 publications

(42 citation statements)

References 20 publications

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“…Xu et al [42] conducted machining experiments in CFRP and proved that the feed rate has the most significant influence on the cutting force that closely correlates with delamination and burr formation. They confirmed and validated these findings in Xu et al [43] too.…”

Section: Introductionsupporting

confidence: 81%

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Geier

2020

Int J Adv Manuf Technol

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Machining of carbon fibre reinforced polymer (CFRP) composites is extremely difficult, mainly due to their inhomogeneous and anisotropic properties. Predicting of cutting force during machining of CFRP is also difficult because the machinability properties of the composite are significantly orientation-dependent (fibre and machining directions). The main objective of the present study is to analyse the influence of fibre orientation on cutting force in milling of unidirectional CFRP. Up and down milling experiences were conducted based on a full factorial design. Experimental data were processed by fast Fourier transformation, regression analysis, and graphical adequate analysis. Multiple-order polynomial models were developed in order to minimise cutting force. Experimental results show that fibre orientation angle significantly influences the cutting force; furthermore, it does not have a significant effect on the passive force component, while the radial force component is more sensitive to the fibre orientation at up milling, than at down milling. An optimal condition is recommended for zig-zag milling of unidirectional CFRPs.

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Section: Introductionsupporting

confidence: 81%

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Geier

2020

Int J Adv Manuf Technol

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“…Helix angle also contributes to reducing the cutting forces. The most common helix angle ranges between 12 to 38 depending on the application [117]. Moreover, the contact area of the drilled hole increases as the drill's diameter increases which subsequently, increases the thrust force and more delamination [52].…”

Section: Role Of Drill Tool Geometry Tool Materials and Coatingsmentioning

confidence: 99%

Recent advances in drilling of carbon fiber–reinforced polymers for aerospace applications: a review

Aamir

Tolouei‐Rad

Giasin³

et al. 2019

Int J Adv Manuf Technol

220

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Drilling is considered as one of the more challenging problems in the aerospace structures stringent tolerance required for fasteners such as rivets and bolts to join the mating parts for the final assembly. Fiber-reinforced polymers are widely used in aeronautical applications due to their superior properties. One of the major challenges lays in the machining such polymers is the poor drilled-hole quality which reduces the strength of the composite and leads to part rejection at the assembly stage. In addition, rapid tool wear due to the abrasive nature of composites requires frequent tool change which result in high tooling and machining costs. This review intended to give in-depth details on the progress of drilling of fiber-reinforced polymers with special attention given to carbon fiber reinforced polymers. The objective is to give a comprehensive understanding of the role of drilling parameters and composite properties on the drilling induced damage in machined holes. Also, the review looks into the drilling process parameters and its optimization techniques, and the effects of dust/ aerosols on human health during the machining process. This review will provide the scientific and industrial communities with their advantages and disadvantages through better drilled-hole quality inspection.

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“…Figure 5 plots the typical mechanisms of material removal process in terms of CFRP and metal cutting. 33 It can be noted that the cutting essence of CFRP is quite different from that of traditional metals when engaged with the rotary tools due to its meso-heterogeneity and macro-anisotropy. In general, fiber crack, resin removal and interface debonding constitute the overall material removal process for CFRP cutting.…”

Section: Resultsmentioning

confidence: 99%

Hole quality and tool wear when dry drilling of a new developed metal/composite co-cured material

Zou

Dang

Cai³

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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The new developed metal/composite co-cured material composed of carbon fiber–reinforced plastic and Al phases has been increasingly applied for manufacturing of attitude control flywheel in aerospace industry. However, drilling of co-cured material is still a challenging task to produce holes with high quality and low cost in the assembly chain and dynamic balance debugging of attitude control flywheel. In other words, the relevant mechanisms and experimental findings involved in the drilling process of carbon fiber–reinforced plastic/Al co-cured material is not clearly defined, which impedes the progress of attitude control flywheel production. To this end, this article specially addresses the experimental studies on the drilling process of carbon fiber–reinforced plastic/Al co-cured material with standard TiAlN-coated cemented carbide twist drill. The significance of this work aims to reveal the regardful cutting responses of the hole characteristics and tool wear modes during the practical drilling process of co-cured material. A full factorial experiment including three levels of feed rate and four levels of cutting speed was performed. The hole diameter shows different values in different positions while it indicates consistent pattern regardless of the cutting variables: the largest in the Al phase, followed by the upper and lower carbon fiber–reinforced plastic phases, respectively. Grooves and matrix degradation are the major machining defects for carbon fiber–reinforced plastic layers, while a great chip debris adhered to the machined surface is the case for Al layer. Subsequent wear analysis showed that abrasion was mainly maintained at the vicinity of major/minor cutting edges and drill edge corner, followed by chip adhesion on the chisel edge region. Carbide substrate of drill flank face is exposed, and thereafter cavities are formed under the strong mechanical abrasion. These results could provide several implications for industrial manufacturers during the attitude control flywheel production.

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An investigation of drilling high-strength CFRP composites using specialized drills

Cited by 82 publications

References 20 publications

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Influence of fibre orientation on cutting force in up and down milling of UD-CFRP composites

Recent advances in drilling of carbon fiber–reinforced polymers for aerospace applications: a review

Hole quality and tool wear when dry drilling of a new developed metal/composite co-cured material

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