Chip Morphology and Delamination Characterization for Vibration-Assisted Drilling of Carbon Fiber-Reinforced Polymer

Hussein, Ramy; Sadek, A.; Elbestawi, M.A.; Attia, Helmi

doi:10.3390/jmmp3010023

Cited by 8 publications

(5 citation statements)

References 33 publications

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“…For all machining conditions, VAD resulted in a lower entry delamination factor compared to CD, as shown in Figures 15 and 16. Based on the defined aerospace limitation (ϕ d ≤ 0.5) [39,51], the delamination factor in CD was acceptable until drilled hole number 20 for N = 37.68 m/min, which is correlated to 460 N thrust force, as shown in Figure 15b. Increasing the cutting speed to 56.52 m/min reduced the entry delamination for f = 0.025 mm/rev by an average of 50%, which remained within the acceptable limit for all tool wear levels.…”

Section: Cfrp Entry Delaminationmentioning

confidence: 99%

An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

Hussein

Sadek

Elbestawi

et al. 2019

JMMP

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The use of lightweight material such as CFRP/Ti6Al4V in stacked structures in the aerospace industry is associated with improved physical and mechanical characteristics. The drilling process of nonuniform structures plays a significant role prior to the assembly operation. However, this drilling process is typically associated with unacceptable CFRP delamination, hole accuracy, and high tool wear. These machining difficulties are attributed to high thermal load and poor chip evacuation mechanism. Low-frequency vibration-assisted drilling (LF-VAD) is an advanced manufacturing technique where the dynamic change of the uncut chip thickness is used to manipulate the cutting energy. An efficient chip evacuation mechanism was achieved through axial tool oscillation. This study investigates the effect of vibration-assisted drilling machining parameters on tool wear mechanisms. The paper also presents the effect of tool wear progression on drilled hole quality. Hole quality is described by CFRP entry and exit delamination and hole accuracy. The results showed a significant reduction in the thrust force, cutting torque, cutting temperature, and flank wear-land.This wear mechanism was attributed to hard and soft abrasion modes [14]. The hard mode is located at WC grains due to the generated dynamic stresses from the broken fiber, material reinforcement, and powder like chips [15]. Consequently, the WC grains suffer crack initiation and propagation fracture [16]. On the other hand, the relatively low hardness Co binder is more easily damaged by carbon fibers (CF) in a process known as soft abrasion mode [14,17,18]. Hence, WC grain spalling is more rapid under the cyclic machining load.High cutting temperature, poor chip evacuation mechanism, and burr formation are of the common issue during the drilling process of Ti6Al4V [19][20][21]. These problems resulted in a higher probability of flute-chip accumulation, progressive tool wear, and poor surface integrity [19,20,22]. Low thermal conductivity and high chemical affinity to the majority of tool materials are due to the adverse titanium characteristics, which resulted in a significant reduction in the tool life with a high probability of catastrophic failure [20,23,24]. This effect contributed to the cutting stress concentration on the tool cutting edge where the maximum cutting temperature is located. Therefore, the machining process of Ti6Al4V is typically associated with the formation of built-up-edge (BUE). The formation of BUE has a significant drawback on the machined surface integrity and the tool life [25,26]. Thus, adding more limitations in the aerospace production procedure [27].Despite, the extensive to optimize separate machining process of both materials, the machining process suffers when it comes to production time, cost, and assembly positional error. Single process drilling of the CFRP and Ti6Al4V materials in situ, also known as stacked drilling shows considerable benefits to overcome separate drilling issues [1][2][3]28,29]. However, the stack drilling o...

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Section: Cfrp Entry Delaminationmentioning

confidence: 99%

An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

Hussein

Sadek

Elbestawi

et al. 2019

JMMP

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“…Table 3 presents the effect of tool wear on the exit delamination for different vibration amplitudes and cutting speeds. The delamination factor (φ d ) was identi ed based on the following equation [21,39]:…”

Section: Effect Of Tool Wear On the Exit Delaminationmentioning

confidence: 99%

The effect of MQL on tool wear progression in low-frequency vibration-assisted drilling of CFRP/Ti6Al4V stack material

Hussein¹,

Sadek²,

Elbestawi³

et al. 2021

Preprint

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In this paper, the tool wear mechanism in low-frequency vibration-assisted drilling (LF-VAD) of carbon fiber reinforced polymer (CFRP)/Ti6Al4V stacks has been proposed using variably machining parameters. Based on the kinematics analysis, the effect of vibration amplitude on the chip formation, uncut chip thickness, chip radian, and axial velocity was presented. Subsequently, the effect of LF-VAD on the cutting temperature, tool wear, delamination, and geometrical accuracy was presented for different vibration amplitude. The LF-VAD with the utilization of minimum quantity lubricant (MQL) resulted in a successful drilling process of 50 holes, with a 63 % reduction of the cutting temperature. For the rake face, LF-VAD reduced the adhered height of Ti6Al4V by 80 % at low cutting speed and reduced the crater depth by 33 % at the high cutting speed. On the other hand, LF-VAD reduced the flank wear land by 53 %. Furthermore, LF-VAD showed a significant enhancement on the CFRP delamination, geometrical accuracy, and burr formation.

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“…Aveen et al [ 12 ] propounded that improper delamination emerged due to the feed rate increase. Hussain et al [ 13 ] worked on the drilling performance of carbon‐fiber reinforced polymers (CFRP) and remarked that high‐frequency vibration‐assisted drilling was an effective technique to decline the thrust force levels. Gururaja et al [ 14 ] proposed a new finite element model to find the cutting force and delamination for multi‐directional polymer composite laminates.…”

Section: Introductionmentioning

confidence: 99%

A comprehensive investigation of drilling performance of anisotropic stacked glass‐carbon fiber reinforced hybrid laminate composites

et al. 2023

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Among the various renewable energy sources, wind energy offers an effective solution to the energy providers. Onshore wind turbines are generally designed for sites with low wind resources, while offshore wind turbines can be more efficient in producing energy thanks to their longer blades that provide more than 10 MW of rated power. Offshore wind turbine blades are subjected to significantly higher stresses and harsh environmental conditions. Therefore, hybrid composites composed of carbon and glass fibers can offer cost-effective and long-lasting solutions for wind turbine blade manufacturers. Turbine blades are connected with main spars through bolted connections and high interlaminar stresses occurring during the drilling process can cause to delamination in the composites. To prevent catastrophic failure related to defective machining, the drilling process must be performed meticulously and all machining-related results must be analyzed step by step. In this paper, dry drilling properties of hybrid glass-carbon fiber laminate epoxy matrix composites were examined experimentally in order to contribute to the wind energy sector. The results showed that the delamination factor could be decreased with higher cutting speeds or lower feed rates. Besides, higher feed levels caused higher thrust forces on the tool body.

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Chip Morphology and Delamination Characterization for Vibration-Assisted Drilling of Carbon Fiber-Reinforced Polymer

Cited by 8 publications

References 33 publications

An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

The effect of MQL on tool wear progression in low-frequency vibration-assisted drilling of CFRP/Ti6Al4V stack material

A comprehensive investigation of drilling performance of anisotropic stacked glass‐carbon fiber reinforced hybrid laminate composites

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