On the interpretation of drilling CFRP/Ti6Al4V stacks using the orthogonal cutting method: Chip removal mode and subsurface damage formation

Xu, Jinyang; Mansori, Mohamed El; Voisin, Julien; Chen, Ming; Ren, Fei

doi:10.1016/j.jmapro.2019.05.052

Cited by 46 publications

(14 citation statements)

References 17 publications

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“…Both damages are generated mainly by the load instabilities due to the compressive loads (thrust force component) on the machining, which produce interlaminar delamination. Interlaminar delamination is far more critical in the external plies, where there is no backup laminate, and this effect was already highlighted and described by Xu et al [38]. Figure 6; Figure 7 show images of the tested materials, corresponding to 2 perpendicular planes of the machined surface for the tests at cutting speeds of 1 m/min and 200 m/min, and feeds of 0.05 mm and 0.2 mm, for the two tested cutting tools.…”

Section: Surface Integritymentioning

confidence: 76%

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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Section: Surface Integritymentioning

confidence: 76%

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

et al. 2019

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“…3. In contrast, cutting from the titanium to the composite is confirmed beneficial for the metallic chip evacuation and hence the improvement of the stack hole quality [9,29,30]. However, such findings are contrary to the observation of the stack orthogonal cutting.…”

Section: Chip Separation Mechanismsmentioning

confidence: 77%

“…As shown in Fig. 8, the CFRP → Ti drilling induces severe composite surface damage close to the interface zone due to the scratching effects of the titanium chip evacuation [29]. By contrast, the interface damage promoted in the Ti → CFRP drilling sequence is limited owing to the avoided effects of the metallic chip ejection.…”

Section: Surface Quality Attributesmentioning

confidence: 98%

“…This means that the machining mechanisms of the stacks cannot be simply considered as the combination of the chip removal modes for the individual composite and titanium phases, particularly for the drilling operation. To understand the operating cutting mechanisms of CFRP/Ti stacks, Xu and his co-authors [15,29,46,[49][50][51][52][53] have sought to utilize the orthogonal cutting method to inspect the chip separation modes governing the machining of these composite-metallic stacks. In their work, both the experimental observations and the numerical simulations were adopted to reveal the underlying mechanisms of the stack chip formation process.…”

Section: Chip Separation Mechanismsmentioning

confidence: 99%

“…As such, machining of these multilayer stacks with desired quality has been a challenging task in the modern aerospace community. Particular issues arise from the inferior surface quality leading to the large proportion of part rejections and the rapid tool wear leading to the short tool life as well as high costs [26][27][28][29][30].…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

A Review on the Machinability of Aerospace-Grade CFRP/Titanium Stacks

Xu¹,

Chen²,

Davim³

et al. 2021

Adv. Mater. Lett.

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The effect of hole‐making process on the performance of CFRP/Ti multi‐bolt joints and load distribution

Wang,

Gao,

Zou

et al. 2024

Polymer Composites

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The CFRP/Ti multi‐bolt joints are commonly used in important structural parts of aircraft. These structure often adopts an integrated drilling method to improve manufacturing efficiency and avoid assembly problems. However, significant differences in material properties between CFRP and titanium alloy can affect hole accuracy, leading to deviations in hole‐size that impact joint performance. In response to these challenges, this study conducted experiments on the hole‐making process for CFRP/Ti laminated multi‐bolt joints and analyzed hole‐size characteristics and precision. The research investigated the effect of hole‐making processes on the static tensile and fatigue performance of CFRP/Ti three‐bolt single‐lap joints specimens and revealed the influence of hole‐size characteristics on load distribution among bolts. Results indicated that titanium alloy chip formation during CFRP hole drilling induced a microcutting effect on CFRP hole walls, resulting in stepped holes. The use of low‐frequency vibration‐assisted drilling improved chip removal and enhanced hole‐making precision. The use of the LDR‐LDR‐CD combined hole‐making process can mitigate the secondary bending phenomenon of critical bolt in CFRP/Ti three‐bolt, single‐lap joints specimens, thereby reducing local stress concentrations. This process combination effectively distributes bolt loads evenly, resulting in a reduction of the bolt load ratio in critical holes by 6.2%, and increases ultimate load and fatigue life by 6.7% and 47.7%, respectively. Therefore, in the hole‐making process of CFRP/Ti multi‐bolt joints, it is crucial to ensure that the precision of critical holes is lower than that of auxiliary holes to decrease the bolt load ratio in critical holes and enhance structural joint performance.Highlights Novel method for uniformly distributing load based on controlling drilling precision. The formation process of CFRP/Ti hole diameter characteristics in different processes. The LDR‐LDR‐CD can optimize load distribution, improve ultimate load and fatigue life.

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On the interpretation of drilling CFRP/Ti6Al4V stacks using the orthogonal cutting method: Chip removal mode and subsurface damage formation

Cited by 46 publications

References 17 publications

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

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

A Review on the Machinability of Aerospace-Grade CFRP/Titanium Stacks

The effect of hole‐making process on the performance of CFRP/Ti multi‐bolt joints and load distribution

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