Hole Surface Quality and Damage When Drilling Unidirectional CFRP Composites

2012 ◽  
Author(s):  
Eshetu D. Eneyew ◽  
M. Ramulu
Keyword(s):  
Significant Variation ◽  
Thrust Force ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Surface Damage ◽  
Fiber Reinforced Plastic ◽  
Reinforced Plastic ◽  
Cfrp Composite ◽  
Cutting Direction

In this study, an experimental investigation on the drilling of unidirectional carbon fiber reinforced plastic (UD-CFRP) composite was conducted using polycrystalline diamond (PCD) tipped eight facet drill. The quality of the drilled hole surface was examined through surface roughness measurements and surface damage by scanning electron microscopy (SEM). It was found that, fiber pullout occurred in two specific sectors relative to the angle between the cutting direction and the fiber orientation. The thrust force was highly influenced by the feed rate than the cutting speed and it shows a significant variation throughout the rotation of the drill.

Effect of Cutting Speed on the Face Milling of CFRP Using a PCD Tool

2016 ◽  
Vol 874 ◽  
pp. 487-491
Author(s):  
Takayuki Kitajima ◽  
Takumi Horiuchi ◽  
Akinori Yui ◽  
Yosuke Ito
Keyword(s):  
Mechanical Characteristics ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Face Milling ◽  
Fiber Reinforced Plastic ◽  
Pcd Tool ◽  
Reinforced Plastic ◽  
The Face ◽  
Cutting Speeds

Carbon-fiber-reinforced plastic (CFRP) is used in various industries such as aerospace and automobile industries because of its high mechanical characteristics. However, this material is difficult to cut. Tool wear and delamination frequently occur during the drilling or cutting of CFRP. In previous studies, we developed a CFRP cutting tool using polycrystalline diamond (PCD). The PCD tool exhibited excellent cutting performance at cutting speeds as low as <120 m/min. In this study, the authors investigated the effect of cutting speed on the face milling of CFRP by using the developed PCD tool.

EXPERIMENTAL STUDIES ON THRUST FORCE AND TORQUE DURING DRILLING OF GLASS FIBER REINFORCED PLASTIC WITH SIC FILLERS

2010 ◽  
Vol 09 (01) ◽  
pp. 63-72 ◽  
Author(s):  
M. SENTHIL KUMAR
Keyword(s):  
Thrust Force ◽  
Experimental Studies ◽  
Cutting Speed ◽  
Gfrp Composites ◽  
Glass Fiber Reinforced Plastic ◽  
Fiber Reinforced Plastic ◽  
Glass Fiber Reinforced ◽  
Reinforced Plastic ◽  
Influencing Parameters ◽  
Twist Drills

The paper discusses the study on thrust force and torque while drilling GFRP composites with SiC fillers. The input parameters such as cutting speed, feed rate and point angle were varied and influencing parameters such as thrust force and torque were studied. The experimental investigation was made during the drilling of GFRP with SiC fillers using four standard twist drills of point angles 90°, 100°, 110° and 120°.

Assessment of Hole Quality and Thrust Force when Drilling CFRP/Al Stack Using Carbide Tools

2012 ◽  
Vol 234 ◽  
pp. 28-33 ◽  
Author(s):  
Sina Alizadeh Ashrafi ◽  
Safian Sharif ◽  
Yahya Mohd Yazid ◽  
Ali Davoudinejad
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Composite Plates ◽  
Machining Performance ◽  
Coated Tools ◽  
Reinforced Plastic ◽  
Metal Chips ◽  
Drilling Conditions

Drilling composite materials is challenging due to the anisotropic and non-homogenous structure of composites. In fabrication works, metals are joined to composites to form a hybrid strengthened structures, and this posed a great problem during drilling, due to the dissimilar drilling conditions for each material and also sharp metal chips effect on the quality of hole on composite plates. This paper evaluates the experimental results on the machining performance of coated and uncoated 4 facet carbide drills when dry drilling stack of carbon fiber reinforced plastic (CFRP) and aluminum. Drilling trials were carried out on CFRP/Al2024/CFRP stack at constant cutting speed of 37 m/min with three feed rates within 0.03-0.25 mm/rev. Results revealed that 4 facet coated drills performed better than uncoated drills in terms of delamination. It was found that hole entry delamination increases with increasing feed rate, however uncut fibers which were dominant at low feeds on hole exit, disappears with increasing feed rate. It was also found that thrust force for coated tools were quite higher than uncoated tools.

Machinability of drilling T700/LT-03A carbon fiber reinforced plastic (CFRP) composite laminates using candle stick drill and multi-facet drill

2015 ◽  
Vol 29 (10n11) ◽  
pp. 1540031 ◽  
Author(s):  
Cheng-Dong Wang ◽  
Kun-Xian Qiu ◽  
Ming Chen ◽  
Xiao-Jiang Cai
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Composite Laminates ◽  
Thrust Force ◽  
Spindle Speed ◽  
Carbon Fiber Reinforced Plastic ◽  
Fiber Reinforced Plastic ◽  
Reinforced Plastic ◽  
Drilling Parameters ◽  
Cfrp Composite

Carbon Fiber Reinforced Plastic (CFRP) composite laminates are widely used in aerospace and aircraft structural components due to their superior properties. However, they are regarded as difficult-to-cut materials because of bad surface quality and low productivity. Drilling is the most common hole making process for CFRP composite laminates and drilling induced delamination damage usually occurs severely at the exit side of drilling holes, which strongly deteriorate holes quality. In this work, the candle stick drill and multi-facet drill are employed to evaluate the machinability of drilling T700/LT-03A CFRP composite laminates in terms of thrust force, delamination, holes diameter and holes surface roughness. S/N ratio is used to characterize the thrust force while an ellipse-shaped delamination model is established to quantitatively analyze the delamination. The best combination of drilling parameters are determined by full consideration of S/N ratios of thrust force and the delamination. The results indicate that candle stick drill will induce the unexpected ellipse-shaped delamination even at its best drilling parameters of spindle speed of 10,000 rpm and feed rate of 0.004 mm/tooth. However, the multi-facet drill cutting at the relative lower feed rate of 0.004 mm/tooth and lower spindle speed of 6000 rpm can effectively prevent the delamination. Comprehensively, holes quality obtained by multi-facet drill is much more superior to those obtained by candle stick drill.

Deterioration of polycrystalline diamond tools in milling of carbon-fiber-reinforced plastic

2016 ◽  
Vol 51 (16) ◽  
pp. 2277-2290 ◽  
Author(s):  
Zhenyuan Jia ◽  
Youliang Su ◽  
Bin Niu ◽  
Yu Bai ◽  
Guangjian Bi
Keyword(s):  
Carbon Fiber ◽  
Diamond Tool ◽  
Cutting Speed ◽  
Tool Material ◽  
Polycrystalline Diamond ◽  
Carbon Fiber Reinforced Plastic ◽  
Fiber Reinforced ◽  
Fiber Reinforced Plastic ◽  
Reinforced Plastic ◽  
Carbon Fiber Reinforced

The cutting edge of the polycrystalline diamond tool easily blunts in high-speed milling of carbon-fiber-reinforced plastic with the tool deterioration. It aggravates the burrs damage due to the change in the tool–material interaction. Therefore, this paper analyzes the tool–material interaction in milling of carbon-fiber-reinforced plastic based on the material-removal mechanism to investigate the tool deterioration mechanism. It reveals that there are two main reasons for the tool deterioration: the extreme crashing and ploughing of the uncut fibers on the tool, and the serious impact of fibers strongly supported on the cutting edge. An indirect measure method is proposed to quantify the tool deterioration including the ploughing-caused wear and impact-caused microchipping. Furthermore, the milling tests are performed to evaluate the tool deterioration under different cutting speeds in the range of 7.33–9.42 m/s. Meanwhile, a modified mathematical model of tool life is proposed based on a strict burr specification in milling of the carbon-fiber-reinforced plastics. Polycrystalline diamond tool has the longest life with the run-in wear and the quasi-steady-state wear for 7.33 m/s cutting speed, and the life rapidly decreases with the increase in the cutting speed in this range. For the cutting speed larger than 8.37 m/s, the wear resistance of polycrystalline diamond tool is very low, because the accelerated state wear occurs instead of the quasi-steady-state wear. Thus, the optimization of the tool geometry and the assisted lubrication should be applied for its improvement.

Effect of Surface Play on the Quality of the Hole when Drilling Multi-Directional CFRP Composites

2013 ◽  
Vol 330 ◽  
pp. 117-122
Author(s):  
Eshetu D. Eneyew ◽  
M. Ramulu
Keyword(s):  
Composite Laminates ◽  
Thrust Force ◽  
Woven Fabric ◽  
Drilling Process ◽  
Pull Out ◽  
Reinforced Plastic ◽  
Cfrp Composite ◽  
Fabric Surface ◽  
Effect Of Surface

The effect of surface ply on the quality of the hole produced when drilling multi-directional carbon fiber reinforced plastic (CFRP) composite laminates was investigated. A series of drilling experiments are performed using a carbide drill tool on two multi-directional CFRP composite laminates. The two composite laminates have similar stacking sequence except the surface plies, namely woven fabric and fiberglass scrim. The thrust force and torque was collected during the drilling process. The quality of the drilled hole was examined through surface roughness measurement, fiber pull out, and delamination. Thrust force was found to be higher for the composite laminate with woven fabric surface plies. The exit delamination factor measured from the holes with woven fabric surface plies found to be lower than the holes with fiberglass scrim surface plies.

Study on UV Laser Cutting Carbon Fibre Reinforced Composites

2014 ◽  
Vol 633-634 ◽  
pp. 738-742
Author(s):  
Li Jun Yang ◽  
Chao Jian Hou ◽  
Ming Zhang ◽  
Wei Qiang Chen ◽  
Yang Wang
Keyword(s):  
Laser Cutting ◽  
Single Photon ◽  
Cutting Speed ◽  
Infrared Laser ◽  
Reinforced Composites ◽  
Uv Laser ◽  
Reinforced Plastic ◽  
Cutting Direction ◽  
Fibre Reinforced Composites

Obtaining narrower kerf and smaller heat affected zone (HAZ) is a difficulty in laser cutting carbon fiber reinforced plastic (CFRP) composites. In order to solve this problem, the experiments used a semiconductor UV laser to cut CFRP have been done and how laser parameters (include pulse power, repetition frequency, cutting speed and direction) influent the width and HAZ of kerf have been achieved. In the meantime, compared with infrared laser cutting CFRP, the quality of CFRP cut by different wavelength laser has been investigated. The results show that owing to CFRP has the characteristic of anisotropy, laser cutting direction is the most significant factor that affects the quality of kerf cut by UV laser. The study also found that owing to high single photon energy, the narrower kerf and smaller HAZ around kerf can be get by UV laser cutting CFRP, nevertheless, it can’t be achieved by infrared laser cutting CFRP.

scholarly journals Multiple Sensor Monitoring of CFRP Drilling to Define Cutting Parameters Sensitivity on Surface Roughness, Cylindricity and Diameter

Materials ◽  
2020 ◽  
Vol 13 (12) ◽  
pp. 2796 ◽  
Author(s):  
Miguel Álvarez-Alcón ◽  
Luis Norberto López de Lacalle ◽  
Francisco Fernández-Zacarías
Keyword(s):  
Composite Materials ◽  
Carbon Fiber ◽  
Electric Power ◽  
Thrust Force ◽  
Cutting Speed ◽  
Carbon Fiber Reinforced Plastic ◽  
Machining Parameters ◽  
Fiber Reinforced ◽  
Fiber Reinforced Plastic ◽  
Reinforced Plastic

Machining parameters affects the final quality of components made in carbon fiber reinforced plastic (CFRP) composite materials. In this framework, the work here presented aims at studying the right combination of cutting speed (vc) and feed rate (vf), for dry drilling of carbon fiber reinforced plastic composite materials, which obtained better results regarding roughness, hole cylindricity, and diameter. A series of experimental tests were carried out under different drilling conditions (vc/vf), monitoring the thrust force (Fz), torque (T), and electric power (EP), to define which one can help more for industrial daily life production. Results validation was carried out using the analysis of variance, in order to relate main machining parameters cutting speed and linear feed, with thrust force, drilling torque, main spindle electric power and hole quality parameters (average roughness, cylindricity and diameter). The conclusions show that thrust force is not proportional to the cutting speed and the best combinations of cutting speed and feed were found out around the average values of tested parameters. Spindle electric power is an interesting element to take into account because it is easy to consider in real production.

Monitoring of hole surface integrity in drilling of bi-directional woven carbon fiber reinforced plastic composites

2020 ◽  
Vol 234 (12) ◽  
pp. 2432-2458 ◽  
Author(s):  
Tarakeswar Barik ◽  
Kamal Pal ◽  
Smruti Parimita ◽  
Priyabrata Sahoo ◽  
Karali Patra
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Thrust Force ◽  
Internal Surface ◽  
Carbon Fiber Reinforced Plastic ◽  
Fiber Reinforced ◽  
Fiber Reinforced Plastic ◽  
Reinforced Plastic ◽  
Circularity Error ◽  
Drill Point

Fiber-reinforced plastic is one of the top priorities lightweight materials with excellent mechanical properties for the aerospace industries in recent years. However, it is difficult to machine despite having unique properties due to its non-homogeneous and abrasive nature in alternate fiber and matrix layers. Thus, it is found to be a challenging task to drill hole on such hard-to-machine materials, which is highly essential for the development of most of the engineering structural components. The present work addresses various drilling-induced defects such as delamination, circularity error, and roughness variations in the hole surface during drilling of quasi-isotropic cross-fiber oriented bi-directional woven-type carbon fiber reinforced plastic laminate using a full factorial design of experiments for different drill geometry. The response surface methodology was considered for the regression model development, which was found to be highly significant. The machining forces with associated torque have also been acquired during drilling, which was divided and further analyzed in time domain to correlate with drilling flaws. The drilling-induced delamination was found to be higher at a high feed rate using a higher drill point angle due to substantial thrust force generation at the initial stages in the drilling cycle. However, the internal surface finish with associated circularity error was reduced for higher spindle speed with less feed rate using a low drill point angle because of low torque fluctuation at the final drilling phases. The axial thrust force was found to be a prime indicator of drilled hole surface delamination, whereas drilling torque precisely indicated internal surface roughness as well as circularity error. The global root mean square, along with a local peak of thrust and torque, both were highly essential to completely characterize the drilled hole quality.

Sign in / Sign up

Export Citation Format

Share Document