Performance of Tools Design when Helical Milling on Carbon Fiber Reinforced Plastics (CFRP) Aluminum (Al) Stack

Abstract

Abstract. Hole making process is not strictly to the drilling technique where others machining could also influence to the quality in CFRP hole.Therefore, helical milling process becomes as an alternative method to produces bore on CFRP plate thus minimizing the defects. The common defects on CFRP are delamination, splintering and cracking. Meanwhile, if the CFRP stacking together with aluminum plate, burr at exit hole of aluminium plate is produced. Therefore, it is essential to control the critical machining parameters to assure a good quality of the hole. The main objective of this project is to improve the hole quality of CFRPIAL stack in terms of surface roughness using helical milling technique. In addition the cutting force and temperature will be measured as well. There are three levels of cutting speeds; two levels of feed rate and depth per helical path are made accordingly to helical milling characteristics. It was found that all tool design exhibit comparable performance for helical milling process on CFRPIAI stack.

Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack

“…This result is in agreement with results in the literature [33]. This is due to the higher hardness of the aluminum panel (250 HV) compared to the carbon composites panel (180 HV) [34], resulting in lower impact on the fiber while drilling CFRP [35]. The thrust force of CFRP obtained from this experiment ranges from 87.69 N to 126.18 N, whereas for Al7075-T6, it varies between 218.21 N and 375.54 N. From the obtained result, R2 has the lowest CFRP peak thrust force, while R7 generates the lowest Al7075-T6's peak thrust force value.…”

“…The average surface roughness (Ra) was used as a measurement parameter in this study. In general, the acceptable surface roughness is an Ra value of CFRP and Al7075-T6 below 3 µm and 1 µm, respectively [35]. The hole surface roughness for both CFRP and Al7075-T6 for both runs are presented in Figure 6.…”

Effect of cutting edge geometry change due to tool wear on hole quality in drilling of carbon fiber reinforced plastics using advanced ceramic coated tools

“…It was reported that hole quality defects caused by the drilling process, such as hole diameter errors, entry/exit delamination, and fiber-pull outs/tearing out, have been responsible for rejecting almost 60% of the composite parts in production. 15,16 Generally, hole quality from fiber reinforced plastics (FRP) drilling is influenced by multiple factors, such as drill type/geometry, fiber/resin properties, process conditions, and cutting forces/vibrations. Many studies focus on the formation mechanisms of delamination, varied by the drilling process conditions.…”

“…It was reported that hole quality defects caused by the drilling process, such as hole diameter errors, entry/exit delamination, and fiber-pull outs/tearing out, have been responsible for rejecting almost 60% of the composite parts in production. 15 , 16…”

The Effects of Cutting Parameters on Surface Texture of Hybrid Composite CFRP/AL2024

“…Carbon fibre reinforced plastics (CFRP) and Fibre metal laminates (FMLs)are often used in various applications of aircraft components and structures due to their high mechanical properties material. Both of thesesuperior substitutes materials are widely adoptedwhen compared to conventional materials required in lighter structural aircrafts; thereby improving fuel efficiency but still retaining the integrity of the structure.The poor surface quality, geometry defects and work piece damage thatare normally found in metalsmay cause the long-term performance of this kind of materialsto be degraded [1] [2]. Aluminium grade 2024 and 7075 are normally used as a core or skinmaterial of FMLs due to malleability and have excellent machinability compared to carbon fibers itself.…”