Numerical study of interface damage formation mechanisms in machining CFRP/Ti6Al4V stacks under different cutting sequence strategies

Xu, Jinyang; Lin, Tieyu; Li, Linfeng; Ji, Min; Davim, J. Paulo; Geier, Norbert; Chen, Ming

doi:10.1016/j.compstruct.2022.115236

Cited by 34 publications

(15 citation statements)

References 54 publications

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“…Higher feed ensures thicker chip to slide by CFRP hole wall [ 13 ]. The authors in [ 9 , 89 ] pointed out that the drilling sequence CFRP →Ti or Ti → CFRP is a significant factor that affects hole diameter because of the chip removal mechanism. However, the distribution of hole diameter in Ti alloy was not sensitive to feed.…”

Section: Resultsmentioning

confidence: 99%

Application of ANN for Analysis of Hole Accuracy and Drilling Temperature When Drilling CFRP/Ti Alloy Stacks

et al. 2022

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Drilling of Carbon Fiber-Reinforced Plastic/Titanium alloy (CFRP/Ti) stacks represents one of the most widely used machining methods for making holes to fasten assemblies in civil aircraft. However, poor machinability of CFRP/Ti stacks in combination with the inhomogeneous behavior of CFRP and Ti alloy face manufacturing and scientific community with a problem of defining significant factors and conditions for ensuring hole quality in the CFRP/Ti alloy stacks. Herein, we investigate the effects of drilling parameters on drilling temperature and hole quality in CFRP/Ti alloy stacks by applying an artificial neuron network (ANN). We varied cutting speed, feed rate, and time delay factors according to the factorial design L9 Taguchi orthogonal array and measured the drilling temperature, hole diameter, and out of roundness by using a thermocouple and coordinate measuring machine methods for ANN analysis. The results show that the drilling temperature was sensitive to the effect of stack material layer, cutting speed, and time delay factors. The hole diameter was mainly affected by feed, stack material layer, and time delay, while out of roundness was influenced by the time delay, stack material layer, and cutting speed. Overall, ANN can be used for the identification of the drilling parameters–hole quality relationship.

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Section: Resultsmentioning

confidence: 99%

Application of ANN for Analysis of Hole Accuracy and Drilling Temperature When Drilling CFRP/Ti Alloy Stacks

et al. 2022

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“…In practical applications, there may be a certain thickness gap between CFRP layer and Ti layer, so it is necessary to establish an interface layer in the simulation model to simulate this gap. The constitutive behavior of the interface is defined by the traction-separation law, and the constitutive behavior can be described as follows [26].…”

Section: Modeling For the Interface Layermentioning

confidence: 99%

Numerical Study of Step Drill Structure on Machining Damage in Drilling of CFRP/Ti Stacks

Chen,

Zhao,

Wang

et al. 2023

Materials

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The tool structure is an important factor affecting the damage of CFRP/Ti stacks machining. However, the impact of tool structure on the formation process of stacks hole damage cannot be fully revealed through experimental methods alone. In contrast, finite element simulation can effectively overcome the limitations of experiments. In this study, a numerical simulation model is established to investigate the relationship between step drill structure and formation process of CFRP/Ti stacks hole damage. Based on this, the research discusses the effect of step drill structure on the burr height of Ti layer, delamination of CFRP, aperture deviation, defects in hole surface. The results show that when the stacking sequence is CFRP to Ti, the burr height of Ti at hole exit decreases first and then increases with the rising of the ratio of primary drill bit diameter to secondary drill bit diameter (kd). When kd is 0.6, the burr height of Ti at hole exit is the lower. As kd increasing from 0.4 to 1.0, delamination factor of CFRP increases by 2.57%, which are affected little by the step drill structure due to the support of Ti. Besides, the aperture size deviation decreases first then increases with the rising of kd, and the minimum aperture size deviation is 2.09 μm when kd is 0.6. In addition, as kd is 0.6, the hole wall defect is fewer. In conclusion, step drill with kd of 0.6 is suitable for drilling of CFRP/Ti stacks.

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“…Working as structure components, CFRP plates are usually connected and assembled with titanium alloy plates forming as CFRP/Ti stacks. For these stack structures, bolting and riveting are common methods for assembling, which requires huge amount of drilling operations [ 4 ]. According to statistics, more than 60% of the scrapped parts in the assembly process are caused by unqualified holes [ 5 ].…”

Section: Introductionmentioning

confidence: 99%

A Study on Drilling of CFRP/Ti Stacks: Temperature Field and Thermal Damage of the Interface Region

et al. 2023

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Carbon fiber reinforced plastics (CFRP)/titanium alloy (Ti) stacks have been widely used in aviation field due to the superior mechanical properties. During integrated drilling of CFRP/Ti stacks, serious damage occurs in the CFRP layer because of the disparate properties of two stack components. Heat accumulation and thermal induced damage are typical and critical issue during drilling stacks, especially in the interface region. In this study, in order to deeply analyze the thermal influence of the interface region, a numerical model based on the finite difference method is developed to predict the three-dimensional drilling temperature field. Experiments with accurate measurement point are conducted to valid the rational of temperature prediction model. The results confirm that the temperature distributions predicted by numerical study have good agreements with the experimental results and the maximum error is about 10.3%. Furtherly, based on the drilling experiments, it can be found that thermal damage induced by cutting heat occurs as discoloration rings around the hole which could cause the elastic modulus of resin matrix decrease. An empirical model of thermal damage with maximum drilling temperature of the interface region are developed with the correlation of R2 = 0.97. The findings point out that as the maximum drilling temperature exceeds 410 °C, serious thermal damage could occur in the resin matrix of CFRP layer.

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Numerical study of interface damage formation mechanisms in machining CFRP/Ti6Al4V stacks under different cutting sequence strategies

Cited by 34 publications

References 54 publications

Application of ANN for Analysis of Hole Accuracy and Drilling Temperature When Drilling CFRP/Ti Alloy Stacks

Application of ANN for Analysis of Hole Accuracy and Drilling Temperature When Drilling CFRP/Ti Alloy Stacks

Numerical Study of Step Drill Structure on Machining Damage in Drilling of CFRP/Ti Stacks

A Study on Drilling of CFRP/Ti Stacks: Temperature Field and Thermal Damage of the Interface Region

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