A critical review of the drilling of CFRP composites: Burr formation, characterisation and challenges

Poór, Dániel István; Geier, Norbert; Pereszlai, Csongor; Xu, Jinyang

doi:10.1016/j.compositesb.2021.109155

Cited by 116 publications

(34 citation statements)

References 109 publications

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“…While the burr factor correlates with the specific area of machining-induced burr, the contour burr factor correlates with the specific length of the contour of the damaged area. The latter may provide indirect but quantitative information on the level of destruction of the uncut composite [27]. Representative processed images of burrs are shown in Fig.…”

Section: Drilling-induced Burrsmentioning

confidence: 99%

“…They showed that the larger the feed, the larger the burr area, because the larger feeds increase the thrust force and the cutting temperature; thus, the softened fibres get buckled easier and form more burrs. Nevertheless, the influence of feed on burr is unclear, as burr formation is not related directly to the chip cross-section; it is more influenced by proper clamping of the composite, solid embedding of the fibres and tool geometry [27].…”

Section: Introductionmentioning

confidence: 99%

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Drilling of recycled carbon fibre–reinforced polymer (rCFRP) composites: analysis of burrs and microstructure

Geier

Poór

Pereszlai

et al. 2022

Int J Adv Manuf Technol

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Since governments encourage sustainability, industries are making great efforts to reuse or recycle carbon fibre–reinforced polymer (CFRP) composites. Despite the promising early results concerning the material properties of recycled CFRP, there is no published knowledge available about their machinability. In this study, drilling-induced micro and macro-sized geometrical defects were analysed and compared in virgin and recycled CFRP. A total of 180 drilling experiments were carried out using uncoated solid carbide cutting tools. Six different CFRP composites were tested at different feeds. The burr characteristics and microstructure were analysed by optical and scanning electron microscopy. The analysis of variance (ANOVA) results suggest that the formation of drilling-induced burrs in CFRP reinforced by recycled chopped and nonwoven mats is less pronounced than in virgin CFRP. Micro- and macro-sized geometrical defects in both recycled and virgin milled CFRP were negligible. This study found no relevant objection to using recycled CFRP from the point of view of drilling-induced burrs and microstructure damage.

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Section: Drilling-induced Burrsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Drilling of recycled carbon fibre–reinforced polymer (rCFRP) composites: analysis of burrs and microstructure

Geier

Poór

Pereszlai

et al. 2022

Int J Adv Manuf Technol

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“…To ensure the proper service life of joints, the drilled holes in FRP/metal stacks must satisfy certain quality parameters [ 6 , 7 ]. These quality parameters are hole diameter [ 8 , 9 , 10 , 11 ], roundness and cylindricity [ 12 , 13 ], surface roughness [ 14 , 15 , 16 ], delamination factor ( F d ) [ 8 , 14 , 17 , 18 ], thermal destruction [ 19 ] and damage value ( Q d ) [ 20 ], and burr height for Ti alloy [ 21 , 22 , 23 ]. Milentiev et al reported the connection between tool geometry and process parameters on delamination factor in CFRP [ 24 ].…”

Section: Introductionmentioning

confidence: 99%

Application of ANN for Analysis of Hole Accuracy and Drilling Temperature When Drilling CFRP/Ti Alloy Stacks

et al. 2022

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Drilling of Carbon Fiber-Reinforced Plastic/Titanium alloy (CFRP/Ti) stacks represents one of the most widely used machining methods for making holes to fasten assemblies in civil aircraft. However, poor machinability of CFRP/Ti stacks in combination with the inhomogeneous behavior of CFRP and Ti alloy face manufacturing and scientific community with a problem of defining significant factors and conditions for ensuring hole quality in the CFRP/Ti alloy stacks. Herein, we investigate the effects of drilling parameters on drilling temperature and hole quality in CFRP/Ti alloy stacks by applying an artificial neuron network (ANN). We varied cutting speed, feed rate, and time delay factors according to the factorial design L9 Taguchi orthogonal array and measured the drilling temperature, hole diameter, and out of roundness by using a thermocouple and coordinate measuring machine methods for ANN analysis. The results show that the drilling temperature was sensitive to the effect of stack material layer, cutting speed, and time delay factors. The hole diameter was mainly affected by feed, stack material layer, and time delay, while out of roundness was influenced by the time delay, stack material layer, and cutting speed. Overall, ANN can be used for the identification of the drilling parameters–hole quality relationship.

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“…Although the drilling-induced burrs do not weaken the resultant strength of the composite, burrs may become a potential starting point for further damage formations (e.g. delamination) and often result in assembly difficulties [19,20]. Composite burrs are often measured and processed through digital image processing of optically captured images [21].…”

Section: Introductionmentioning

confidence: 99%

Analysis of drilling-induced geometrical damages in basalt and carbon fibre-reinforced polymer (BFRP and CFRP) composites

Magyar

Károly

et al. 2022

Int J Adv Manuf Technol

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Basalt fibre-reinforced polymer (BFRP) composites probably tend to replace some carbon fibre-reinforced polymer (CFRP) applications due to their excellent specific strengths and sustainability. Despite the published early promising results concerning the material properties of BFRP, their application is not widespread, and their machinability is not supported widely by published experiences. The main aim of the present study is to experimentally investigate the drilling-induced geometrical damages of BFRP and CFRP composites. Drilling experiments were conducted at various feed and cutting speed levels using a solid carbide twist drill. The drilling-induced burr was analysed by a Mitutoyo 361–804 digital microscope, a Mitutoyo SJ400 surface tester recorded the surface roughness, and the microstructure was analysed by a Zeiss Evo MA 10 scanning electron microscope. The measured data were evaluated through digital image processing (DIP), response surface methodology (RSM), and analysis of variances (ANOVA). The experimental results show that drilling-induced burr is more severe and surface roughness is worse in BFRP than in CFRP. The composite type influenced the geometrical damages primarily, followed by the feed in the case of burrs and by the cutting speed in the case of surface roughness. The present experimental study suggests that the drilling of BFRP is even more challenging than drilling CFRP from the point of view of burr formation and micro geometrical properties.

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A critical review of the drilling of CFRP composites: Burr formation, characterisation and challenges

Cited by 116 publications

References 109 publications

Drilling of recycled carbon fibre–reinforced polymer (rCFRP) composites: analysis of burrs and microstructure

Drilling of recycled carbon fibre–reinforced polymer (rCFRP) composites: analysis of burrs and microstructure

Application of ANN for Analysis of Hole Accuracy and Drilling Temperature When Drilling CFRP/Ti Alloy Stacks

Analysis of drilling-induced geometrical damages in basalt and carbon fibre-reinforced polymer (BFRP and CFRP) composites

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