Mechanistic cutting force modelling for micro-drilling of CFRP composite laminates

Anand, Ravi Shankar; Patra, Karali

doi:10.1016/j.cirpj.2016.07.002

Cited by 64 publications

(24 citation statements)

References 25 publications

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“…In mechanical micro-machining, the effect of the microstructure of the material (material defects; density, type, position, orientation and size of grains/fibres/particles) is significant [62,74,75]. The influences of the microstructure of an anisotropic and an inhomogeneous material are illustrated in Fig.…”

Section: Chip Removal Mechanism In Micro Sizesmentioning

confidence: 99%

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

133

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Recently, mechanical micro-milling is one of the most promising micro-manufacturing processes for productive and accurate complex-feature generation in various materials including metals, ceramics, polymers and composites. The micro-milling technology is widely adapted already in many high-tech industrial sectors; however, its reliability and predictability require further developments. In this paper, micro-milling related recent results and developments are reviewed and discussed including micro-chip removal and micro-burr formation mechanisms, cutting forces, cutting temperature, vibrations, surface roughness, cutting fluids, workpiece materials, process monitoring, micro-tools and coatings, and process-modelling. Finally, possible future trends and research directions are highlighted in the micro-milling and micro-machining areas.

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Section: Chip Removal Mechanism In Micro Sizesmentioning

confidence: 99%

A review on micro-milling: recent advances and future trends

Balázs

Geier

Takács

et al. 2020

Int J Adv Manuf Technol

133

View full text Add to dashboard Cite

show abstract

“…The influences of helix angle, drill core thickness and front angle on drilling force, temperature and chip morphology were analyzed, and the non-coaxial spiral flank micro-drilling geometry was optimized. Anand et al [6,7] established a drilling force and torque prediction model during drilling CFRP; in the process of model establishment, the influence of the blunt circle radius of the cutting edge and the minimum cutting chip thickness on the machining process were considered. The prediction model was verified experimentally with a 0.5-mm-diameter micro-drill.…”

Section: Introductionmentioning

confidence: 99%

Study on hole quality and surface quality of micro-drilling nickel-based single-crystal superalloy

Zhou

et al. 2020

J Braz. Soc. Mech. Sci. Eng.

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Nickel-based single-crystal superalloy has no grain boundary. This makes the traditional cutting mechanism of shearing and slipping along grain boundary of polycrystalline material based on the theory of elastic-plastic deformation not suitable for drilling single-crystal parts. To achieve high-quality and low-damage micro-drilling of nickel-based single-crystal superalloy, the micro-drilling surface/subsurface quality of the (001) crystal plane of nickel-based single-crystal superalloy was studied in this paper. Firstly, the influence rules of the cutting speed (v s) and the feed rate (v w) on the micro-drilling hole size, surface morphology, surface roughness and subsurface damage depth were studied. Then, the micro-hardness on micro-drilling subsurface was analyzed. Finally, the subsurface recrystallization was explored. The results show that with the increase in v s , the hole diameter error and the surface roughness decrease, and the depth of subsurface plastic deformation layer decreases first and then increases; with the increase in v w , the error of hole diameter and the surface roughness increase, and the depth of the deformation layer decreases first and then increases. When v w > 0.33 μm/r, there are severe scratches on the surface of the hole wall, and the hole wall appears undulating stripes; white layer structure and severe plastic deformation layer appeared on the micro-drilling subsurface; the γ and γ' phases' deformation is severe; the micro-hardness at the subsurface white layer is small, and the micro-hardness value at the plastic deformation zone is large; after the hightemperature treatment, γ phase dissolves on the subsurface of micro-drilling parts, and the cellular recrystallization and the complete recrystallization occur. The minimum thickness of recrystallization layer obtained is 1.43 μm at v s = 141 m/min and v w = 0.105 μm/r. This study provides a good guidance and reference for the machining of nickel-based single-crystal superalloy micro-hole parts.

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“…Away from the center at the chisel edge, orthogonal cutting takes place with a negative rake angle [5]. However, the cutting lip cuts material under oblique cutting formulation and with increasing radius outward, the machining parameters change too [6,7]. Figure 1 represents the engagement of chisel edge and cutting lip in the conventional drilling process.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Cutting Process Parameters in Inclined Drilling of Inconel 718 Using Finite Element Method and Taguchi Analysis

2020

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Nickel-based superalloys are famous in the demanding applications. Inconel 718 is one of the most commonly used nickel-based superalloys due to its extraordinary inherent properties. Inconel 718 is a suitable material for high temperature applications due to the properties such as anti-oxidization, high hot hardness, high creep, and fatigue strength. Drilling operation is one of the most widely used manufacturing operations in almost all industrial sectors. However, drilling operation is very complex in nature due to the presence of intricate geometry of the drill bit. In conventional drilling, cutting is performed by the combined action of the chisel edge and the two or more cutting lips. In depth analysis of the cutting process shows that chisel edge starts with an indentation at the center of the twist drill. Then away from the center, chisel edge performs orthogonal cutting with negative rake angle. Whereas, cutting action at the cutting lip is oblique in nature, and force analysis involves the use of element formulation due to involvement of radius. It is rarely found in the literature where drilling operation at different inclination angles is conducted and analyzed. The presented study numerically investigates the cutting performance of drilling operation, when operated at different inclination angles. The study revealed cutting force variation at different inclination angles due to the different tool workpiece engagement for each inclination. The magnitude of thrust force increased when inclination angle is changed from 30° to 60°. It can be linked with the higher chip load initially in this case as compared to the 30° inclination angle. The cutting temperature was affected by spindle speed (53.7%), followed by feed rate (33.31%) and inclination angle (3.44%).

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Mechanistic cutting force modelling for micro-drilling of CFRP composite laminates

Cited by 64 publications

References 25 publications

A review on micro-milling: recent advances and future trends

A review on micro-milling: recent advances and future trends

Study on hole quality and surface quality of micro-drilling nickel-based single-crystal superalloy

Optimization of Cutting Process Parameters in Inclined Drilling of Inconel 718 Using Finite Element Method and Taguchi Analysis

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