An Investigation of Process Performance when Drilling Carbon Fiber Reinforced Polymer (CFRP) Composite under Dry, Cryogenic and MQL Environments

Nagaraj, Arjun; Uysal, Alper; Jawahir, I.S.

doi:10.1016/j.promfg.2020.02.165

Cited by 46 publications

(15 citation statements)

References 12 publications

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“…In addition, when drilling under dry conditions, it is expected that cutting temperature will rise both the cutting tool and the workpiece leading to the expansion of the lamina; however, composites such as CFRP and GFRP have tendency to spring-back leading to shrinkage of drilled holes closer to their nominal diameter [74]. The current results disagree with previous studies [63,[75][76][77][78] on drilling CFRP and GFRP laminates using through tool cryogenic cooling which both reported reduced hole size when using cryogenic cooling compared to dry drilling. This could be attributed to the cooling strategy (i.e., cryogenic bath vs cryogenic through tool cooling) in which the later provides efficient cooling in terms of controlled coolant quantity and localisation on the hole cutting region and cutting tool.…”

Section: Hole Size and Circularity Analysiscontrasting

confidence: 93%

“…This indicates that lower feed rates produce holes with minimum circularity which was also reported in previous studies [60,76]. The increase in hole circularity with increasing feed rate is related to the increase in the thrust force which increases the radial force that have direct influence on the circularity value [76,86]. The effect of feed rate can be seen more clearly in holes drilled under dry conditions due to higher distortions in the hole and drill which steadily deteriorates with an increment in depth below the hole entry surface [87].…”

Section: Hole Size and Circularity Analysissupporting

confidence: 86%

“…For both the drilling conditions, these minimum values were obtained at the moderate n = 5000 rpm and the lowest f r = 300 mm/min. This indicates that lower feed rates produce holes with minimum circularity which was also reported in previous studies [60,76]. The increase in hole circularity with increasing feed rate is related to the increase in the thrust force which increases the radial force that have direct influence on the circularity value [76,86].…”

Section: Hole Size and Circularity Analysissupporting

confidence: 82%

See 2 more Smart Citations

The effect of cryogenic machining of S2 glass fibre composite on the hole form and dimensional tolerances

Köklü

Morkavuk

Featherston

et al. 2021

Int J Adv Manuf Technol

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S2 glass fibre reinforced epoxy composites are widely used in aeronautical applications owing to their excellent strength to weight ratio. Drilling glass fibres can be cumbersome due to their abrasive nature and poor thermal conductivity. Moreover, the use of conventional coolants is not desirable due to contamination and additional costs for cleaning the machine part. An alternative is to use environmentally friendly coolants such as liquid nitrogen (LN2) which have been previously employed in machining metals and composites. The current study investigates the effect of drilling S2 glass fibre composite in a bath of LN2. The study aims to evaluate the effect of spindle speed, feed rate and the presence of cryogenic cooling on the form and dimensional tolerances of the hole (hole size, circularity, cylindricity and perpendicularity). Design of experiments and analysis of variance (ANOVA) were used to determine the contribution of the input parameters on the analysed hole quality metrics. Results indicated that drilling S2 glass fibre in a cryogenic bath increased hole size significantly beyond the nominal hole diameter. The hole circularity and cylindricity were reduced compared to holes drilled under dry condition under all cutting parameters due to enhanced thermal stability during the drilling process. The current study aims to provide the scientific and industrial communities with the necessary knowledge on whether cryogenic bath cooling strategy provides better hole quality output compared to dry drilling and other cryogenic cooling strategies which were previously reported in the open literature.

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Section: Hole Size and Circularity Analysiscontrasting

confidence: 93%

Section: Hole Size and Circularity Analysissupporting

confidence: 86%

Section: Hole Size and Circularity Analysissupporting

confidence: 82%

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The effect of cryogenic machining of S2 glass fibre composite on the hole form and dimensional tolerances

Köklü

Morkavuk

Featherston

et al. 2021

Int J Adv Manuf Technol

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show abstract

“…74,76 Drilling studies on CFRP agree that using cryogenic coolants tend to reduce surface roughness and increase cutting forces and delamination factor. 77,82,83 While previous studies on drilling GFRP in cryogenic environment are limited and reported that using them increased the cutting forces and reduced delamination factor and surface roughness. 35 None of the previous studies in the open literature reported the drilling of S2 glass fibre composites or the impact of cryogenic cooling in particular.…”

Section: Introductionmentioning

confidence: 99%

Microstructural investigation and hole quality evaluation in S2/FM94 glass-fibre composites under dry and cryogenic conditions

Giasin

Barouni

Dhakal

et al. 2020

Journal of Reinforced Plastics and Composites

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S2/FM94 glass fibre reinforced epoxy is an aerospace-grade composite currently bonded with aluminium alloys and installed in parts of the Airbus A380 fuselage. In addition to its abrasive and hard nature, S2/FM94 glass fibre is sensitive to thermal effects developed during the drilling process, and therefore using coolants becomes necessary. However, conventional oil and water-based coolants are not suitable for drilling of composites. Cryogenic coolants on the other hand are an attractive choice for machining composites and are environmentally friendly. In this study, a new environmentally friendly cryogenic cooling technique in a liquid nitrogen bath was used for the drilling of S2/FM94 glass fibre reinforced epoxy composite. The aim was to investigate the effect of drilling parameters and cryogenic cooling on cutting forces, surface roughness, hardness and delamination factor at hole entry and exit sides. The workpiece was drilled within a cryogenic bath. In this way, both cryogenic workpiece cooling and tool cooling were obtained. In addition, the drill geometry is fixed and only the cutting parameters (i.e. spindle speed and the feed rate) are varied under dry and cryogenic conditions. The results indicate that the spindle speed and cryogenic cooling had the most significant influence on the cutting forces and surface roughness parameters (Ra and Rz), while the use of cryogenic cooling had the most significant influence on increasing the hardness and size of delamination at entry and exit sides of the holes.

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“…Various innovative lubrication and cooling methods, for example minimum quantity lubrication (MQL) and cryogenic cooling, are used to effectively reduce temperature, which intensifies build-up and thus increases cutting forces, tool wear, and surface roughness [11]. Research shows that the use of these methods reduces the delamination of polymer matrix composites and improves the roundness and roughness of the drilled holes while increasing tool life [12]. However, other studies showed that the use of MQL could contribute to the delamination of polymer composites [13].…”

Section: Introductionmentioning

confidence: 99%

Drilling of Holes in Aluminum Matrix Composites at Dry and with the Minimum Quantity Lubrication of the Cutting Zone

Karolczak¹,

Poroś²,

Skowronek³

2021

Tribol. Ind.

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Holes in metal matrix composites can be created by unconventional techniques such as EDM or laser drilling. However, these methods do not guarantee the quality of the holes, the production efficiency. The work carried out conventional drilling studies of aluminum matrix composite reinforced with ceramic fibers and the nonreinforced matrix. The tests were made dry and under conditions of minimum quantity lubrication (MQL) of the cutting zone. Oil mist was applied external. The measured and observed machinability indicators were surface roughness, cutting force, hole shape error, and chip shape. It was found that the use of oil mist in drilling improves the shape quality and surface of the holes. The positive effect of lubrication decreases with increased drilling feed. Oil mist slightly reduces cutting resistance and does not change the shape of the chips. It is shown that by drilling holes in aluminum matrix composite under conditions of minimal quantity lubrication, it is possible to achieve such a quality that it is possible to eliminate roughing. An additional advantage of using oil mist is a smaller dispersion of test results, which shows that the treatment with minimal lubrication is more stable.

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An Investigation of Process Performance when Drilling Carbon Fiber Reinforced Polymer (CFRP) Composite under Dry, Cryogenic and MQL Environments

Cited by 46 publications

References 12 publications

The effect of cryogenic machining of S2 glass fibre composite on the hole form and dimensional tolerances

The effect of cryogenic machining of S2 glass fibre composite on the hole form and dimensional tolerances

Microstructural investigation and hole quality evaluation in S2/FM94 glass-fibre composites under dry and cryogenic conditions

Drilling of Holes in Aluminum Matrix Composites at Dry and with the Minimum Quantity Lubrication of the Cutting Zone

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