Comparison of conventional drilling and orbital drilling in machining carbon fibre reinforced plastics (CFRP)

Voß, Robert; Henerichs, Marcel; Kuster, Friedrich

doi:10.1016/j.cirp.2016.04.001

Cited by 73 publications

(23 citation statements)

References 11 publications

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“…Presence of coolant and lubricant also affects the quality of the hole produced. The coolant and tool geometry (Bharti and Moulick, 2013; Voss et al., 2016) have directly influenced on cutting temperature and the tool wear. Effective parameters of the drilling process are tool diameter, cutting speed, feed rate, coolant of drilling process, material type, and cutting tool features.…”

Section: Methodsmentioning

confidence: 99%

Defect evaluation of the honeycomb structures formed during the drilling process

Ghabezi

Farahani

Shahmirzaloo

et al. 2019

International Journal of Damage Mechanics

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In this paper, a comprehensive experimental investigation was carried out to precisely characterize the delamination and uncut fiber in the drilling process. A digital imaging procedure was developed in order to calculate the damage resulted from the drilling process. A novel method is proposed in this article based on image intensity to verify the obtained results. A full factorial experimental design was performed to evaluate the importance of the drilling parameters. Among other process parameters, feed rate, cutting speed, and tool diameter are the principal factors responsible for the delamination damage size during the drilling. The drilling process was assessed based on two proposed incurred damage factors, specifically the delamination factor and uncut fiber factor. Experimental results demonstrated that the feed rate was the paramount parameter for both delamination and uncut fiber factors. It was observed that both factors increased with an increase in the feed rate. Additionally, by increasing the tool diameter, the delamination and uncut fiber factors significantly increase. The effects of the cutting speed on damage factors were not linear. The minimum delamination factor and uncut fiber factor were obtained at the cutting speed of 1500 and 2500 r/min, respectively.

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Section: Methodsmentioning

confidence: 99%

Defect evaluation of the honeycomb structures formed during the drilling process

Ghabezi

Farahani

Shahmirzaloo

et al. 2019

International Journal of Damage Mechanics

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“…Tool paths of helical milling (also known as orbital drilling) are more complex than tool paths of conventional drilling: operation time of helical milling is therefore longer and more time is needed for optimisation [86]. As can be seen on Fig.…”

Section: Conventional Drilling and Helical Milling Of Cfrpsmentioning

confidence: 99%

“…Conventional drilling and helical milling strategies in CFRPs were compared by Voss et al [86]. They found that orbital drilling produces fewer geometrical defects (delamination and uncut fibres) in CFRPs than conventional drilling, which Geier and Szalay [7] also observed.…”

Section: Conventional Drilling and Helical Milling Of Cfrpsmentioning

confidence: 99%

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Pereszlai

Geier

2020

Int J Adv Manuf Technol

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Due to its excellent specific mechanical properties, carbon fibre-reinforced polymer (CFRP) composite is a widely used structural material in the aerospace industry. However, this material is difficult to cut, mainly due to its inhomogeneity and anisotropic features and because of the strong wear effects of its carbon fibres. In the scope of aerospace industrial uses of this material, thousands of holes have to be machined for purposes of assembly. Nevertheless, conventional drilling technologyeven if special drilling tools are usedis only moderately able to manufacture good quality holes. Wobble milling is a novel advanced hole-making technology, which has been developed to minimize machining-induced geometrical defects like delamination or uncut fibres. The main objective of the present paper is to compare wobble milling, helical milling and conventional drilling technologies concerning unidirectional CFRPs. In addition, the kinematics of wobble milling technology is discussed in detail. In the scope of this paper, numerous machining experiments were conducted in unidirectional CFRPs: herein the impact of the type of cutting tool and of process parameters on the quality of machined holes are analysed and discussed (diameter of holes, circularity error and characteristics of uncut fibres). During these investigations, experimental data were evaluated with the help of digital image processing (DIP) and with the help of analysis of variance (ANOVA) techniques. Experimental results show that the amount of uncut fibres can significantly be minimized through the application of wobble milling technology.

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“…A comparison between conventional and orbital drilling of heavy-to-cut unidirectional CFRP parts with diamond coated tools was presented in [ 54 ], focusing on workpiece damages, tool wear, bore diameter variances, as well as cycle times. Orbital drilling generated a better hole quality with lower process forces, but required a more complex/dynamic machine tool and longer process times.…”

Section: Conventional Machining Processesmentioning

confidence: 99%

Machining of Fibre Reinforced Plastic Composite Materials

Caggiano

2018

Materials

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Fibre reinforced plastic composite materials are difficult to machine because of the anisotropy and inhomogeneity characterizing their microstructure and the abrasiveness of their reinforcement components. During machining, very rapid cutting tool wear development is experienced, and surface integrity damage is often produced in the machined parts. An accurate selection of the proper tool and machining conditions is therefore required, taking into account that the phenomena responsible for material removal in cutting of fibre reinforced plastic composite materials are fundamentally different from those of conventional metals and their alloys. To date, composite materials are increasingly used in several manufacturing sectors, such as the aerospace and automotive industry, and several research efforts have been spent to improve their machining processes. In the present review, the key issues that are concerning the machining of fibre reinforced plastic composite materials are discussed with reference to the main recent research works in the field, while considering both conventional and unconventional machining processes and reporting the more recent research achievements. For the different machining processes, the main results characterizing the recent research works and the trends for process developments are presented.

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Comparison of conventional drilling and orbital drilling in machining carbon fibre reinforced plastics (CFRP)

Cited by 73 publications

References 11 publications

Defect evaluation of the honeycomb structures formed during the drilling process

Defect evaluation of the honeycomb structures formed during the drilling process

Comparative analysis of wobble milling, helical milling and conventional drilling of CFRPs

Machining of Fibre Reinforced Plastic Composite Materials

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