Open hole surface integrity and its impact on fatigue performance of Al 2024-T3/Ti-6Al-4V stacks

Ge, Jia; Feist, Toby; Elmore, Alexander; Jin, Yan; Sun, Dan

doi:10.1016/j.procir.2022.03.041

Cited by 6 publications

(3 citation statements)

References 19 publications

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“…Drilling is a commonly used hole making technique that enables fast, precise and reliable assembly of components through mechanical riveting/bolting [1,[36][37][38]. For FRTP, drilling remains the pivotal process for producing reliable mechanical joints between dissimilar materials (such as composite / metal joints) and load bearing components [36].…”

Section: Drillingmentioning

confidence: 99%

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Luo

Catalanotti

et al. 2023

Preprint

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Fibre reinforced thermoplastic polymer (FRTP) composites have been used for a wide range of engineering applications (e.g. in transport, construction, energy, etc) due to their excellent mechanical properties and ease of repair and recycling. In recent years, FRTP is increasingly deployed as an alternative to conventional thermoset carbon fibre reinforced epoxy (CF/epoxy) composites, for the purpose of reducing the carbon footprint and contributing to a sustainable manufacturing agenda. Machining of FRTP remains an indispensable process to achieve rapid parts assembly whilst meeting stringent geometric tolerances. However, due to the heterogeneous structure and high thermal sensitivity of FRTP, a range of machining-induced damages (such as matrix smearing, thermal degradation, delamination, burr and surface cavity) often occur, leading to concerns on machined parts quality and reliability. To date, composite machining studies have been mostly focused on conventional thermoset CF/epoxy and there is a lack of an up-to-date, in-depth review of the latest advancement concerning the machining of FRTP. This paper provides a state-of-the-art overview on the recent developments in FRTP machining over the past decade, with a particular emphasis on machining characteristics, damage mechanisms as well as the challenges facing such manufacturing process. The purpose is to present the composite manufacturing community with a timely update, which may guide and inspire further research and development for future FRTP manufacturing.

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Section: Drillingmentioning

confidence: 99%

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Luo

Catalanotti

et al. 2023

Preprint

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“…Bolar et al [29] reported that the holes produced in CARALL have minimum surface roughness and are characterized by smaller-sized burrs as opposed to the conventional drilling method. Ge et al [30] highlighted that the fatigue life of Al 2024-T3/Ti-6Al-4V stacks with holes produced by helical milling improved two times in comparison to Al 2024-T3/Ti-6Al-4V stacks with holes produced by conventional drilling. Sun et al [31] found in their study that helical milling of Ti/CFRP/Al stacks results in discontinuous chips, allowing for easy chip evacuation and improving the surface quality of the hole produced.…”

Section: Introductionmentioning

confidence: 99%

Performance Analysis of Helical Milling and Drilling Operations While Machining Carbon Fiber-Reinforced Aluminum Laminates

Bolar,

Dinesh,

Polishetty

et al. 2024

JMMP

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Being a difficult-to-cut material, Fiber Metal Laminates (FML) often pose challenges during conventional drilling and require judicious selection of machining parameters to ensure defect-free laminates that can serve reliably during their service lifetime. Helical milling is a promising technique for producing good-quality holes and is preferred over conventional drilling. The paper compares conventional drilling with the helical milling technique for producing holes in carbon fiber-reinforced aluminum laminates. The effect of machining parameters, such as cutting speed and axial feed, on the magnitude of cutting force and the machining temperature during conventional drilling as well as helical milling is studied. It was observed that the thrust force produced during machining reduces considerably during helical milling in comparison to conventional drilling at a constant axial feed rate. The highest machining temperature recorded for helical milling was much lower in comparison to the highest machining temperature measured during conventional drilling. The machining temperatures recorded during helical milling were well below the glass transition temperature of the epoxy used in carbon fiber prepreg, hence protecting the prepreg from thermal degradation during the hole-making process. The surface roughness of the holes produced by both techniques is measured, and the surface morphology of the drilled holes is analyzed using a scanning electron microscope. The surface roughness of the helical-milled holes was lower than that for holes produced by conventional drilling. Scanning electron microscope images provided insights into the interaction of the hole surface with the chips during the chip evacuation stage under different speeds and feed rates. The microhardness of the aluminum layers increased after processing holes using drilling and helical milling operations. The axial feed/axial pitch had minimal influence on the microhardness increase in comparison to the cutting speed.

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“…carbon fibre reinforced poly-etherketone-ketone (CF/PEKK) [10,11], carbon fibre reinforced poly-ether-ether-ketone CF/PEEK [12] and carbon fibre reinforced polyurethane (CF/TPU) [13]) reported various machining induced defects (such as delamination [11], burr [14], thermal degradation [10], fibre debonding [12] and surface cavity [11]), which are highly sensitive to the machining induced high temperatures (up to 200 o C [10,15]). These defects not only affect the parts' surface quality/assembly tolerance, but also compromise their reliability and lead to high part rejection rate [16][17][18]. The rapid tool wear and severe tool clogging associated with CFRTP machining is another significant challenge, which contribute greatly to the increased manufacturing cost and wasteful power expenditure [19,20].…”

Section: Introductionmentioning

confidence: 99%

Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite

Ge,

Tan,

Ahmad

et al. 2023

Preprint

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The global commitment towards reducing carbon emissions drives the implementation of sustainable carbon-fibre-reinforced-thermoplastic composites (CFRTPs). However, the machining of CFRTPs presents challenges due to the material’s ductile-brittle composition and sensitivity to machining-induced high temperatures. For the first time, we conducted temperature-controlled orthogonal cutting of CFRTP (using CF/PEKK as a demonstrator) to unveil its temperature-dependent cutting physics. Three representative cutting temperatures, 23 ℃ (ambient temperature),100 ℃ (< PEKK’s glass transition temperature (Tg)) and 200 ℃ (> Tg) and four typical fibre cutting orientations (0°, 45°, 90°, and 135°) have been investigated. The evolution of chip microstructural morphology and surface/subsurface damage have been analysed by advanced microscopy to reveal temperature-dependent material removal mechanisms. The experimental results were elucidated through a novel microscale finite-element-analysis (FEA) model considering thermal softening of the matrix and interface. Results show the transition of the cutting physics with increasing temperature is associated to the degradation of the thermoplastic matrix stiffness/ultimate strength and interface bonding strength and fracture toughness, especially when > Tg.

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Open hole surface integrity and its impact on fatigue performance of Al 2024-T3/Ti-6Al-4V stacks

Cited by 6 publications

References 19 publications

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Process characteristics, damage mechanisms and challenges in machining of fibre reinforced thermoplastic polymer (FRTP) composites: A review

Performance Analysis of Helical Milling and Drilling Operations While Machining Carbon Fiber-Reinforced Aluminum Laminates

Temperature-dependent cutting physics in orthogonal cutting of carbon fibre reinforced thermoplastic (CFRTP) composite

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