Delamination formation and suppression during rotary ultrasonic elliptical machining of CFRP

Geng, Daxi; Liu, Yihang; Shao, Zhenyu; Zhang, Mingliang; Jiang, Xinggang; Zhang, Deyuan

doi:10.1016/j.compositesb.2019.107698

Cited by 126 publications

(22 citation statements)

References 32 publications

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“…In recent years, the use of composite materials has been increasing in aerospace, aeronautic, naval, and automotive industries. Carbon fiber reinforced polymer (CFRP) has been a key material in many applications due to its excellent attributes such as low weight, excellent fatigue and corrosion resistance, and high strength and chemical resistance [1,2]. CFRPs have been one of the most used in the manufacturing of aircrafts.…”

Section: Introductionmentioning

confidence: 99%

Experimental study of thrust force and surface quality when drilling hybrid stacks

Mahdi

Turki

Habak

et al. 2020

Int J Adv Manuf Technol

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Increasing aircrafts' productivity and reducing their riveting time have created the need of one-shot drilling of dissimilar materials. The present work had followed this strategy on 4 shaft satin weave carbon fiber and epoxy matrix (AS-4 woven CFRP) and aluminum alloy (AA 2189) in order to study the effect of drilling direction on Al and carbon fiber reinforced polymer thrust force evolution and holes' quality. It presents a comparison between CFRP, CFRP/Al, and Al/CFRP results using the same drilling tool and cutting parameters to understand the influence of adding metal layers on CFRP drilling defects. It was observed that the increase of the thrust force is related to cutting parameters. It causes thermal degradation of composite matrix when drilling CFRP/Al, and it impacts the aluminum surface roughness. One-shot drilling strategy does not affect thrust force evolution whenever the layers' position in the stack. Drilling defects exist especially in the composite part such as uncut fibers, chipping, and spalling. It was found that the cutting speed had the dominant influence on surface damage. Holes' quality differs from one configuration to another. Adding Al layer on the top reduces seriously the composite drilling defects and causes groove in the Al holes. Composite matrix smearing was observed when drilling CFRP/Al. It seems that drilling CFRP sheet between to supports improves composite holes' quality.

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Section: Introductionmentioning

confidence: 99%

Experimental study of thrust force and surface quality when drilling hybrid stacks

Mahdi

Turki

Habak

et al. 2020

Int J Adv Manuf Technol

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show abstract

“…The hole entry delamination (peel-up delamination) is mainly related to the flute shape, helical angle, drilling torque and drill vibration, while the hole exit delamination (push-out delamination) is mainly related to the thrust force, interface quality of the laminates and process conditions. Many other researchers have also studied delamination during drilling FPR materials [30][31][32]. By reviewing the above literature, it is found that most of the studies mainly focus on delamination during drilling FPR materials, but the research on uncut fibers and tool wear is still not clear, and there is a deficit in the existing knowledge of the wear mechanisms, including factors that determine the wear resistance of the tool, especially research on hybrid FPR materials, which is still in the exploratory stage.…”

Section: Introductionmentioning

confidence: 99%

Study on Burr Formation and Tool Wear in Drilling CFRP and Its Hybrid Composites

Lee

Song

2021

Applied Sciences

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As contemporary emerging materials, fiber-reinforced plastics/polymers (FRP) are widely used in aerospace automotive industries and in other fields due to their high strength-to-weight ratio, high stiffness-to-weight ratio, high corrosion resistance, low thermal expansion and other properties. Drilling is the most frequently used process in industrial operation for polymer composite laminates, owing to the need for joining structures. However, it is a great challenge for operators to drill holes in FRP materials, due to the non-homogenous and anisotropic properties of fibers. Various damages, such as delamination, hole shrinkage, and burr and tool wear, occur due to the heterogeneous and anisotropic nature of composite laminates. Therefore, in this study, carbon fiber reinforced polymer (CFRP)/aramid fiber reinforced polymer (AFRP) hybrid composites (C-AFRP) were successfully synthesized, and their drilling characteristics, including burr generation and tool wear, were also mainly investigated. The drilling characteristics of CFRP and C-AFRP were compared and analyzed for the first time under the same operating conditions (cutting tool, spindle speed, feed rate). The experimental results demonstrated that C-AFRP had higher tensile strength and good drilling characteristics (low thrust and less tool wear) compared with CFRP. As a lightweight and high-strength structural material, C-AFRP hybrid composites have great potential applications in the automobile and aerospace industries after the slight processing of burrs generated during drilling.

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“…Recently, Liu et al [26] proposed a novel high-speed rotary ultrasonic elliptical milling (HRUEM) method for high-speed (v = 160 m/min) side milling of Ti-6Al-4V alloy with the ultrasonic vibration vertical to the direction of cutting speed. Ultrasonic elliptical vibration in a flat surface perpendicular to a tool axis was imposed on a rotating tool, and an intermittent cutting mode between the tool and the workpiece can be achieved at high cutting speeds due to the overlapping of trajectories for the adjacent cutting tool tips [27,28]. Due to HRUEM's cutting characteristics (reduced cutting temperature and increased lubrication) at high cutting speeds, the penetration of cooling fluid into the cutting area can be effectively enhanced, significantly improving cutting performance.…”

Section: Introductionmentioning

confidence: 99%

High-Speed Rotary Ultrasonic Elliptical Milling of Ti-6Al-4V Using High-Pressure Coolant

Zhang

Guo³

et al. 2020

Metals

Self Cite

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High-speed rotary ultrasonic elliptical milling (HRUEM), as a novel ultrasonic vibration cutting method, has been introduced in milling the alloy Ti-6Al-4V. The application of ultrasonic vibration in high-speed milling can help open the cutting contact area intermittently. New cutting effects will happen with full use of the separation effect brought by ultrasonic vibration and the cooling effect brought by a high-pressure coolant (HPC). On the basis of that, this paper firstly introduces HPC into HRUEM of Ti-6Al-4V in the open literature and analyzes the tool-workpiece separation cooling mechanism in HRUEM, including kinematic analysis of tool tip trajectories, tool-workpiece separation principles and high-pressure coolant effects. We have conducted a comprehensive experimental study and the results show when HPC is increased to 200 bar, compared to conventional milling (CM), the tool life in HUREM can be extended by 6.6 times at 80 m/min, 4.2 times at 120 m/min and 2.4 times at 160 m/min. The maximum material removal volume (MRV) for a given new end mill in HRUEM is increased by 657% approximately. When the cutting speed is 80 m/min, the cutting temperature of the workpiece in HRUEM is reduced by 24.1% compared to that of CM. By applying the combination of HPC and tool-workpiece periodic separation, we can significantly enhance the cooling and lubrication efficiency in HRUEM and also inhibit the tool wear mode of adhesive wear typically occurred in CM.

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Delamination formation and suppression during rotary ultrasonic elliptical machining of CFRP

Cited by 126 publications

References 32 publications

Experimental study of thrust force and surface quality when drilling hybrid stacks

Experimental study of thrust force and surface quality when drilling hybrid stacks

Study on Burr Formation and Tool Wear in Drilling CFRP and Its Hybrid Composites

High-Speed Rotary Ultrasonic Elliptical Milling of Ti-6Al-4V Using High-Pressure Coolant

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