Experimental analysis of drilling damage in carbon-fiber reinforced thermoplastic laminates manufactured by resin transfer molding

Abstract

The emergence of new high-performance thermoplastics to replace thermosets in fiber-reinforced polymers puts up a new challenge: their machining. In this study, carbon fiber-reinforced poly-cyclic butylene terephthalate laminates were manufactured, drilled, and inspected. Different commercial drill geometries and machining conditions were compared. Roughness, microscopy, and non-destructive tests allowed us to determine the hole quality as well as delamination. The surface tests showed better results after working at the most common cutting speed (3000 rpm) than at high speed (15,000 rpm) with a constant feed rate. This fact can be explained based on the viscoelastic properties of the matrix that becomes fragile at high cutting speeds. The Delamination factor obtained by means of Ultrasonics and X-ray Computed Tomography also confirmed that the best results are achieved with a Twist drill bit at 3000 rpm. In contrast to carbon fiber-reinforced thermosets, the detected delamination at high cutting speeds is not as remarkable as expected. These results allow us to conclude that this new composite will certainly increase production rate without delamination damage. Chip formation takes also a special role. It can be recovered to be used as reinforcement in manufacturing processes due to the recyclability of the thermoplastic matrix.

An analytical method for predicting the fluctuation of thrust force during drilling of unidirectional carbon fiber reinforced plastics

“…Since low feed rate may help reducing the delamination, 21 the upper limit of feed rate is made 155 mm/min. The spindle speed, as proved by Khashaba et al 22 and Lopez-Arraiza et al, 23 should be kept in the most common level (less than 3000 r/min) to prevent the deterioration of matrix caused by the generated temperature.…”

Orthogonal cutting of UD-CFRP using multiscale analysis: Finite element modeling

“…The heterogeneity and anisotropic nature of carbon fiber-reinforced polymer (CFRP) composites make the machining process difficult and lead to different damages. 1,2 Thus, the cutting of CFRP needs to be discussed in more details. In the literature, different approaches including experimental and numerical methods have been used to investigate the machining of composites.…”

Fabrication, Characterization and Drilling Operation of Natural Fiber Reinforced Hybrid Composite With Filler (Fly-Ash/Graphene)

“…He has observed that chemical treatment affect the thermal transition temperature. Lopez-Arraiza [32] has developed carbon fibre composite. Drilling operation has been conducted.…”