Effect of cutting edge geometry change due to tool wear on hole quality in drilling of carbon fiber reinforced plastics using advanced ceramic coated tools

Abstract

This paper aims to study the evolution of cutting edge geometry due to tool wear and discuss its impact on the hole quality of a carbon fiber reinforced plastic (CFRP) laminate. A drilling experiment was conducted using three types of twist drills: uncoated, BAM (AlMgB14) coated, and (AlCrSi/Ti)N nanocomposite coated tungsten carbide tools. After generating 120 holes, the uncoated drill had the largest cutting edge radius (∼36 µm), while the BAM coated drill had the most extensive flank wear (∼287 µm) among the three drills. This relatively rapid tool wear results in a reduction of average hole size and a considerable variation on the hole profiles. The worn drills with the cutting edge radius greater than 19.3 µm form the fiber pull-outs in not only the 135° plies but also the adjacent 45° and 90° plies from the cutting direction, creating deep void networks. This type of networked fiber pull-out damage was observed with the holes machined by the uncoated and BAM coated drills. The (AlCrSi/Ti)N coated drill, which experienced the least amount of flank wear and the least increase of cutting edge radius, generated consistently sized holes up to 120 holes. However, the relatively sharp (AlCrSi/Ti)N coated tool results in the higher arithmetic roughness average (Ra) and the maximum roughness height (Rz) values than the other tools due to the localized fiber pull-outs and the absence of severe matrix smearing.

Advances in Ultraprecision Diamond Turning: Techniques, Applications, and Future Trends

“…The choice of coating material and method has a direct impact on the performance and wear characteristics of the tools, influencing their effectiveness in achieving ultraprecision diamond turning. In addition, the impact of cutting edge geometry on tool wear and hole quality in drilling operations has been a subject of study, with research aiming to understand the evolution of cutting edge geometry due to tool wear and its implications for the quality of machined components (Abdullah et al, 2021;Onoyere and Adekanmbi, 2012). This focus on tool wear mechanisms and their influence on the quality of machined parts is crucial in the context of ultraprecision diamond turning, where maintaining high precision and surface quality is paramount.…”

Hard and Highly Adhesive AlMgB14 Coatings RF Sputtered on Tungsten Carbide and High-Speed Steel

“…The most recent advances and new results include the following: hard and lubricant BAM films produced by DC magnetron sputtering of three elemental targets (B, Mg, Al) [16], employing the process of RF plasma sputtering of AlMgB 14 powder targets [17], AlMgB 14 /TiB 2 composite ceramic brazed onto 304 stainless steel using a commercial Ag-CuTi eutectic foil [18], examination of BAM-coated twist drill wear, the evolution of cuttingedge geometry in drilling experiments with carbon-fiber-reinforced plastic (CFRP) laminate [19] and the novel application of BAM-based ceramic coatings onto the blade edges of razor blades [20] and onto the surfaces of rolling elements in bearing assemblies [21]. Especially noteworthy is the deep nanostructural characterization of the mechanical-tribological behavior and the analysis of the wear rate of nanocomposite TiSiCN coatings deposited on high-Co-based high-speed steel (ASSAB 17) burins [22].…”