Investigations on the axial cutting force during drilling of carbon fiber composite material

Wu, Mingyang; Chen, Yong; Guo, Yu; Gao, Yang; Tong, Mulin

doi:10.1177/0954405417690569

Cited by 7 publications

(4 citation statements)

References 21 publications

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“…The application of advanced materials and components with complex geometric shapes in modern industries has driven the demands for new machining methods and new cutting tools. 1–7 Diamond materials provide the ultimate performance and unsurpassed productivity in cutting difficult-to-machine materials such as carbon fiber reinforced plastic (CFRP), 8–10 titanium alloys, 11 nickel-based high-temperature alloys, and ceramic materials, 12 which are widely used in the aerospace, defense, and biomedical industries. 13 Polycrystalline diamond (PCD) is a type of composite material which is made of synthetic diamond particles sintered with metallic binder materials at 1400–1800°C under high pressure of 4–10 GPa.…”

Section: Introductionmentioning

confidence: 99%

Electrical discharge machining of polycrystalline diamond: A review

Wang

Guo

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Owing to its ultra-hardness and exceptional wear resistance, polycrystalline diamond (PCD) is widely used in numerous applications such as bearing, nozzle, metal cutting, oil and gas, and hard rock mining. However, the hardness of diamond means PCD products are incredibly difficult to manufacture. Electrical discharge machining (EDM) is one of the most effective non-traditional methods used for machining PCD materials, although the unique composite structure and low electrical conductivity of PCD lead to low machining efficiency. This paper presents an overview of the methods and newly emerged state-of-the-art technologies to improve material removal rate and surface quality as well as the mechanisms behind these methods. Literature analysis shows that efficiency improvement could be achieved by increasing energy utilization and the sparking gap in EDM. The utilization of discharge energy is highly sensitive to the expansion of single discharge sparks. Further improvement in machining efficiency could be achieved by enhancing discharge expansion and explosive force through changing processing forms, dielectric, electrode shape, and power generator in the future. To provide a comprehensive insight of the machinability of PCD, EDM processes of using PCD as tool electrodes to machine other materials to improve machining performance are also discussed.

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Section: Introductionmentioning

confidence: 99%

Electrical discharge machining of polycrystalline diamond: A review

Wang

Guo

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…However, drilling is still a challenging task for manufacturing engineers due to the varying tool-work interaction when drilling co-cured material. Up to now, many investigations have been reported in terms of composite machining [13][14][15][16][17][18][19][20][21][22][23][24] and composite/metal stack machining. [25][26][27][28][29][30][31] Much attention was in particular paid on the drilling operations of the above materials.…”

Section: Introductionmentioning

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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“…In addition to machining of polycarbonate, polypropylene, and epoxy matrix composites with various reinforcements, there have been several recent studies on machinability of carbon fiber-reinforced polymer (CFRP) composites. Majority of the research studies have focused on investigating the drilling performance of CFRPs, [33][34][35][36] while few studies have focused on milling machinability of CFRPs. 37,38 Although there have been several studies on the SPDT and grinding of polycarbonates, the focused application area was optical lenses.…”

Section: Introductionmentioning

confidence: 99%

Tool wear and resulting surface finish during micro slot milling of polycarbonates using uncoated and coated carbide tools

Jahan

Hanson

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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A growing application of polycarbonates is in the microfluidic disks and DNA detection devices, where surface finish of the micro-channels plays an important role. This study intends to investigate the tool wear and surface finish generated during micro slot milling of polycarbonate using uncoated, TiN-coated, and TiAlN-coated tungsten carbide tools. The effects of tool coating and the machining parameters on the possible reduction of tool wear and improvement of surface finish were investigated. It was found that with careful selection of cutting parameters and tool coating, micro-channels with smoother surface finish, minimum burrs around the edges, and controlled tool wear can be obtained using micro-milling. A combination of medium range of depth of cut and feed rate was found to improve the surface finish in polycarbonates, as well as minimize the tool wear. The TiAlN tool coating was found to only be effective in reducing tool wear without much effect on the machined surface. The adhesion was found to be the most dominating tool wear mechanism in uncoated carbide tool, followed by cutting edge chipping and tool nose’s plastic failure. The adhesion wear was found to be reduced in coated tools, especially in TiAlN-coated tools, although delamination wear started to dominate in the coated tools when higher feed rate and depth of cut were used. Both lower and higher of depths of cut were found to generate higher tool wear and leave traces of tool marks on the machined surface.

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Investigations on the axial cutting force during drilling of carbon fiber composite material

Cited by 7 publications

References 21 publications

Electrical discharge machining of polycrystalline diamond: A review

Electrical discharge machining of polycrystalline diamond: A review

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

Tool wear and resulting surface finish during micro slot milling of polycarbonates using uncoated and coated carbide tools

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