Numerical analysis of the influence of tool wear and special cutting geometry when drilling woven CFRPs

Feito, Norberto; Díaz-Álvarez, José; López-Puente, J.; Miguélez, M.H.

doi:10.1016/j.compstruct.2015.11.065

Cited by 70 publications

(33 citation statements)

References 32 publications

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“…Abrão et al [57] showed that 56% of the tools used for drilling polymer composites have a special geometry. Some of the special drilling tools developed for CFRP cutting are as follows: (i) double point angle twist drills [58][59][60][61][62][63][64], (ii) brad and spur drills [21,[65][66][67][68][69][70], (iii) dagger drills (one-shot drills) [28,31,[67][68][69][70][71][72][73], (iv) step drills [67,68,[74][75][76][77][78][79][80], (v) core drills [81,82] and (vi) special core drills [83][84][85]. These special drilling tools are reviewed and discussed in detail by Geier et al [55].…”

Section: Conventional Drilling and Helical Milling Of Cfrpsmentioning

confidence: 99%

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Pereszlai

Geier

2020

Int J Adv Manuf Technol

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Due to its excellent specific mechanical properties, carbon fibre-reinforced polymer (CFRP) composite is a widely used structural material in the aerospace industry. However, this material is difficult to cut, mainly due to its inhomogeneity and anisotropic features and because of the strong wear effects of its carbon fibres. In the scope of aerospace industrial uses of this material, thousands of holes have to be machined for purposes of assembly. Nevertheless, conventional drilling technologyeven if special drilling tools are usedis only moderately able to manufacture good quality holes. Wobble milling is a novel advanced hole-making technology, which has been developed to minimize machining-induced geometrical defects like delamination or uncut fibres. The main objective of the present paper is to compare wobble milling, helical milling and conventional drilling technologies concerning unidirectional CFRPs. In addition, the kinematics of wobble milling technology is discussed in detail. In the scope of this paper, numerous machining experiments were conducted in unidirectional CFRPs: herein the impact of the type of cutting tool and of process parameters on the quality of machined holes are analysed and discussed (diameter of holes, circularity error and characteristics of uncut fibres). During these investigations, experimental data were evaluated with the help of digital image processing (DIP) and with the help of analysis of variance (ANOVA) techniques. Experimental results show that the amount of uncut fibres can significantly be minimized through the application of wobble milling technology.

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Section: Conventional Drilling and Helical Milling Of Cfrpsmentioning

confidence: 99%

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Pereszlai

Geier

2020

Int J Adv Manuf Technol

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“…Bu durum kompozit malzemelerin özgül kesme dirençlerinin düşük olmasına bağlıdır. Karbon fiber takviyeli kompozit malzemeler işlenirken kesme kuvvetlerinin düşük çıkması literatürle örtüşen bir durumdur [23,24]. Şekil 7'deki grafik incelendiğinde kesme hızındaki artış genel olarak kesme kuvvetlerinin düşmesine sebep olmuştur.…”

Section: Kesme Kuvvetlerinin Değerlendirilmesi (Evaluation Of Cuttingunclassified

Karbon fiber takviyeli kompozit (KFTK) malzemelerin frezelenmesinde delaminasyon ve kesme kuvvetlerinin değerlendirilmesi ve matematiksel modellenmesi

Yağmur

Kurt

Şeker

2019

Gazi Üniversitesi Mühendislik Mimarlık Fakültesi Dergisi

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Highlights:Graphical/Tabular Abstract  Milling of carbon fiber reinforced composites  Effects of different geometry tools on delamination  ANOVA statistics for delamination and cut3Nowadays, weight reducing is become possible with composite materials taking placeof steel (60-80) and aluminum (20-50%). Composite materials have become the preferred materials for many engineering applications. However, besides the advantages of composite materials, there are problems in manufacturing.Manufacturing of fiber-reinforced composite materials are more difficult than other materials. This situation needs to be very selective in terms of cutting tools. In this study, contour millind was realized of carbon fiber reinforced composite materials with PCD cutting tolls. Delamination and cutting forces have been studied investigated. After the experiments, it has been seen that increasing the cutting speed has a positive effect on the delamination, cutting forces and the best performance has shown the T1. According to ANOVA statistics, the most effective parameter in terms of delamination is cutting speed. According to ANOVA statistics, the most effective parameter in terms of cutting forces is second clearance angle. A schematic representation of the experimental setup is shown in Figure 1. Figure A. Schematic representation of the experimental setupPurpose: In this study, a unique PCD cutting tool design was devised which is capable of eliminating the encountered difficulties, especially the delamination problem on laminated/laminar formed composite board during machining carbon fiber reinforced composite (CFRC) materials. And cutting tools performance has been investigated in terms of delamination and cutting forces. Theory and Methods:Contour milling of KFTK materials was carried out with PCD cutting tools. The experiments were performed at the CNC vertical machining center. Three different cutting speed and constant feed rate used in experiments. Results:T1 tool has shown the best performance in terms of delamination and cutting forces between the designed and manufactured of the cutting tools. The best result in terms of delamination occurred at a cutting speed of 450 m / min with T1 tool. Cutting speed increase positively influenced delamination and cutting forces. According to model results the most important parameter affecting delamination is the cutting speed Conclusion:The performance of the designed and manufactured cutting tools are very good. The T1 coded cutting tool has the best performance among these cutting tool.

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“…At the same time, the high costs associated with experimental tests are reduced. However, many numerical models found in the literature have been developed to simulate machining processes, which involve rotary cutting movements, such as turning [17,18] or drilling [19]. In these cases, it is difficult to obtain experimental information about the effect of the orientation of the fibers on the tool and on the workpiece, so the differences between the experimental test and the conditions considered in the model definition reduce the precision of the model.…”

Section: Introductionmentioning

confidence: 99%

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

et al. 2019

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Carbon Fiber-reinforced plastics (CFRPs) are widely used in the aerospace industry due to their highly mechanical properties and low density. Most of these materials are used in high-risk structures, where the damage caused by machining must be controlled and minimized. The optimization of these processes is still a challenge in the industry. In this work, a special cutting device, which allows for orthogonal cutting tests, with a linear displacement at a wide range of constant cutting speeds, has been developed by the authors. This paper describes the developed cutting device and its application to analyze the influence of tool geometry and cutting parameters on the material damage caused by the orthogonal cutting of a thick multidirectional CFRP laminate. The results show that a more robust geometry (higher cutting edge radius and lower rake angle) and higher feed cause an increase in the thrust force of a cutting tool, causing burrs and delamination damage. By reducing the cutting speed, the components with a higher machining force were also observed to have less surface integrity control.

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Numerical analysis of the influence of tool wear and special cutting geometry when drilling woven CFRPs

Cited by 70 publications

References 32 publications

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Karbon fiber takviyeli kompozit (KFTK) malzemelerin frezelenmesinde delaminasyon ve kesme kuvvetlerinin değerlendirilmesi ve matematiksel modellenmesi

A New Cutting Device Design to Study the Orthogonal Cutting of CFRP Laminates at Different Cutting Speeds

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