Prediction model of chisel edge thrust force and material damage mechanism for interlaminar-direction drilling of UD-CFRP composite laminates

Li, Shujian; Dai, Longyu; Li, Changping; Chen, Rong; Qiu, Xinyi; Li, Pengnan; Ko, Tae Jo

doi:10.1016/j.compstruct.2022.116023

Cited by 25 publications

(5 citation statements)

References 35 publications

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“…The regression coefficients (R 2 ) of the advanced models are 0.6751 and 0.8481 for the BFRP and CFRP, respectively. The R 2 of the CFRP composite model is in the range achieved by similar research works [37,[39][40][41][42]; thus, it is accurate enough to use. Although the method for the model building of the BFRP and CFRP composites is identical, the R 2 of the BFRP becomes significantly smaller than that of CFRPs.…”

Section: Comparison and Discussionmentioning

confidence: 70%

Analysis and modelling of thrust force in drilling of basalt and carbon fibre-reinforced polymer (BFRP and CFRP) composites

Magyar

Geier

2023

J Braz. Soc. Mech. Sci. Eng.

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Currently, the use of sustainable products and technologies is growing; consequently, mineral-origin basalt fibre-reinforced polymer (BFRP) composites are becoming more popular in industries. Although BFRP parts require mechanical drilling operations for manufacturing holes for assembly, many challenges make the drilling process difficult. Considering that the cutting force is one of the main parameters characterising the drilling process, this study aims to analyse the influence of feed (mm/rev) and cutting speed (m/min) on the thrust force and model the thrust force in the drilling of BFRP composites through response surface methodology (RSM) and advanced statistical modelling methods. In order to determine main and interaction effects and to calculate the regression coefficients and model parameters, mechanical drilling experiments were performed, and the thrust force was recorded. The raw force data were processed using fast Fourier transformation-based low-pass filtering, and then the calculated thrust force parameters were evaluated relative to various feeds and cutting speeds. In addition, results were compared with those of carbon fibre-reinforced polymer composites. The results of the validation experiments show that both RSM and advanced statistical models accurately predict the thrust force in BFRPs of 96.74% and 95.01%, respectively. However, the advanced statistical model can describe not only the maximum values of the force but also its characteristics at a coefficient of determination of 0.68.

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Section: Comparison and Discussionmentioning

confidence: 70%

Analysis and modelling of thrust force in drilling of basalt and carbon fibre-reinforced polymer (BFRP and CFRP) composites

Magyar

Geier

2023

J Braz. Soc. Mech. Sci. Eng.

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“…The machinability of CFRP is notorious [8], [9] due to its inhomogeneity, anisotropic nature and different composed phase properties of carbon fiber phase and matrix phase, which results in some easily detected defects including fiber pull-out, matrix cracking, burrs and delamination [2], [10], [11]. Beside of this, extrinsic factors, including tool geometry [12], [13], [14], [15], [16], [17], tool material, support plates [18], [19], [20], machining parameters [12], [21], [22] and workpiece shapes [23], [24], can also influence the machined surface during drilling CFRPs.…”

Section: Machinability Of Carbon Fiber Reinforced Polymer (Cfrp)mentioning

confidence: 99%

Experimental research on the matrix cracks and delamination distribution and their monitoring methods during drilling UD-CFRP

Liu,

Qin,

et al. 2023

Preprint

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Although carbon fiber reinforced polymer (CFRP) has been widely used in various applications, it is still regarded as a kind of difficult to cut material due to its vulnerability to machining damages. In the current research, CFRP drilling experiments was conducted and found that the matrix cracks and delamination were observed not only at the entrance and exit of holes, but also in the middle area of the holes. Therefore, it is necessary to study the distribution of these defects due to the severe effect on the mechanical properties of CFRP. In this paper, the distribution of these defects as well as their monitoring methods were investigated. First, four factors were introduced to locate the distribution of these defects that were observed by X-ray CT scanner. Then, Statistical Process Control (SPC) was applied for damage detection with features optimized sensitivity analysis. Finally, the performance of SPC was validated, which has a high damage identifying accuracy of 86.78% and recommended for the on-line application.

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“…11–16 However, excessively high drilling speeds can result in rapid tool wear and burn marks on the hole wall. 17 Other researchers have focused on tooling and machining methods. For example, Fernandes et al 18 reported that gun drills combined the advantages of low axial force, sharp cutting edges, and fast chip evacuation, which allowed them to quickly cut through fibers and reduce tearing and burrs at the entry and exit of the holes.…”

Section: Introductionmentioning

confidence: 99%

A study on the ultrasonic vibration on the cutting performance during ultrasonic-assisted drilling of CFRP with twist and dagger drill bits

Mao,

Jia,

Zhang

2024

Advances in Mechanical Engineering

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During the drilling process of carbon fiber reinforced polymer (CFRP), defects such as exit delamination, tearing, and burrs are prone to occur, among which excessive axial force during drilling is the main reason for the generation of exit delamination defects. In this study, ultrasonic-assisted and conventional drilling with twist and dagger drills were investigated on 5 mm-thick multi-directional laminated fiber sheets made of T300-12k/AG80 carbon fiber composite with different orientations. The axial force evolutions in each case were monitored when drilling holes in CFRP plates, and the axial force of drilling and the appearance characteristics of hole outlet were compared. The experimental results showed that the ultrasonic assisted drilling reduced the axial drilling forces of twist and dagger drill by up to 20.6% and 30.7%, respectively, compared to conventional drills. In addition, as the feed rate increases, the axial force of drilling gradually increases, and the exit delamination factor shows an overall increasing trend. The ultrasonic vibrations reduced the exit delamination damage of both drills. A special structure of the dagger drill effectively avoided exit delamination during ultrasonic-assisted drilling, which makes the incision more neat to improve the processing quality.

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Prediction model of chisel edge thrust force and material damage mechanism for interlaminar-direction drilling of UD-CFRP composite laminates

Cited by 25 publications

References 35 publications

Analysis and modelling of thrust force in drilling of basalt and carbon fibre-reinforced polymer (BFRP and CFRP) composites

Analysis and modelling of thrust force in drilling of basalt and carbon fibre-reinforced polymer (BFRP and CFRP) composites

Experimental research on the matrix cracks and delamination distribution and their monitoring methods during drilling UD-CFRP

A study on the ultrasonic vibration on the cutting performance during ultrasonic-assisted drilling of CFRP with twist and dagger drill bits

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