Experimental study on drilling process of a newly developed CFRP/Al/CFRP co-cured material

Zhong, Bingfu; Zou, Fan; An, Qinglong; Chen, Ming; Zhang, Hongzhou; Xie, Changsong

doi:10.1016/j.jmapro.2021.12.062

Cited by 12 publications

(10 citation statements)

References 27 publications

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“…Similar results were found by Zhong et al, since the amount of delamination obtained with uncoated tool in their work was almost 4 – eight folds that of TiAlN coated tool. 46 The ta-C coating is not completely exfoliated even after 100 holes and the presence of coating on the tool surface of the micro-ta-C coated drill is confirmed by energy-dispersive X-ray (EDX) analysis, as shown in Figure 12. Moreover, the choice of the metallic dopant (i.e.…”

Section: Resultsmentioning

confidence: 90%

“…It can be explained by the reduction of wear probability due to the high hardness and high bonding strength of this coating type. High hardness can spread out and reduce thrust force, and a reduced thrust force can efficiently result in a lower 46 The ta-C coating is not completely exfoliated even after 100 holes and the presence of coating on the tool surface of the micro-ta-C coated drill is confirmed by energy-dispersive X-ray (EDX) analysis, as shown in Figure 12. Moreover, the choice of the metallic dopant (i.e.…”

Section: Coating Characterizationmentioning

confidence: 99%

“…As mentioned by Feito et al and Zhong et al, the thrust force contributing throughout the drilling process causes the exit delamination to be greater than the entry delamination. 4,46 Thus, current study focused only on delamination at the exit side of the CFRP panel.…”

Section: Coating Characterizationmentioning

confidence: 99%

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Characterization of nanocomposite tetrahedral amorphous carbon coated drill bits for improved drilled-hole quality in carbon fiber-reinforced polymer/Al7075-T6 stacks

Jebaratnam,

Hassan,

Mahmud

et al. 2023

Journal of Composite Materials

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The use of hybrid composite stacks is kept on increasing in the aircraft industry due to their numerous advantages in this sector. Therefore, improving the drilled-hole quality is also sought over time. The present work focuses on the effect of metallic elements-doped tetrahedral amorphous carbon coated drill bits on the drilled-hole quality while performing single-shot drilling of CFRP/Al7075-T6 stacks. This was evaluated from CFRP exit delamination and Al7075-T6 exit burr height. Mechanical and tribological properties of three different tetrahedral amorphous carbon (ta-C) coating-types, i.e. micro-, chromium-doped (:Cr) and titanium-doped (:Ti) were compared to uncoated tool ones. Bonding strength of the selected coatings with the tool was also calculated. Process capability six pack analysis was used to validate the experimental results obtained for drilled-hole quality. It was shown that micro-ta-C coating-type exhibited maximum hardness. The hardness value directly influences the exit delamination. It was found that CFRP exit delamination decreased as the hardness of the drill bit increased. Moreover, the multi-material stacks drilled with ta-C:Cr coated tool presented the lowest burr height (less than 150 µm), compared to the other tested coating-types. Low-friction surfaces seem to promote low exit burr height.

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Section: Resultsmentioning

confidence: 90%

Section: Coating Characterizationmentioning

confidence: 99%

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Characterization of nanocomposite tetrahedral amorphous carbon coated drill bits for improved drilled-hole quality in carbon fiber-reinforced polymer/Al7075-T6 stacks

Jebaratnam,

Hassan,

Mahmud

et al. 2023

Journal of Composite Materials

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“…When individually considering the effect of each drill bit on the roughness of the holes in this study, all the drill bits produce mostly larger hole surface roughness in carbon fibre reinforced polymer than in aluminium panel and this pattern is significant with uncoated drill bit. This could be due to the anisotropy property of the carbon fibre reinforced polymer material [38] or chip produced during the drilling of aluminium alloy deteriorated the carbon fibre reinforced polymer hole surface [61,62]. A previous research also supported this fact by obtaining roughness of less than 0.6 μm in metal and 2.8 μm in carbon fibre reinforced polymer part with diamond coated drill [50].…”

Section: Hole Surface Roughnessmentioning

confidence: 88%

A comparative study of hole integrity performance in composite‐metal stacks using coated and uncoated tungsten carbide drill bits

Mathavan,

Hassan,

Mahmud

2024

Materialwissenschaft Werkst

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This study aims to develop tetrahedral amorphous carbon nanocomposite layer coated tungsten carbide drill bits for single shot drilling of composite metal stack. Different coatings were tested for hole integrity performance compared to an uncoated tool and the results were validated using process capability six‐pack analysis. The drilling process employed a 4.85 mm twist drill with a feed rate of 0.05 mm/rev and spindle speed of 2600 rev/min. The experimental results indicate that, all the coated tools produce H9 tolerance holes while uncoated tool produced H7 tolerance holes with 18 % to 35 % better results. But statistical results show that all the tools including uncoated tool require improvement to stay within the control limits. The hole circularity error obtained by all the tools were below 24 μm in both the panels and is supported by the statistical results as well. The uncoated tool exhibited 17.91 % better surface roughness in aluminium panel compared to coated tools, while coated tools produced 17.2 % to 22.3 % better surface roughness in composite panel. Statistical results suggested that, improvement is necessary when drilling aluminium panel by all the tools while dopant added coated tools produce better results in composite panel.

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“…Composite materials and metallic materials are often assembled together by mechanical connection, such as riveting, bolt connection, the accuracy of hole making and surface defects directly affect the reliability of mechanical connection. 3,4 The aircraft structural parts are subjected to complex mechanical and thermal loading environment in flight, among which the tensile load is the main load. Conventional machining processes generally employed for cutting composites are drilling and milling.…”

Section: Introductionmentioning

confidence: 99%

Investigation of tensile property and strain distribution of drilled carbon fiber reinforced polyetheretherkrtone composites

Yang

Liu

2023

Journal of Composite Materials

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Tool geometry can significantly influence hole quality during drilling of CFRP laminates, which has impact on mechanical properties. In this paper, drilling experiments with different drill bit geometries (twist, brad and dagger drill) are carried out on carbon fiber reinforced polyetheretherketone (CF/PEEK) composites. The influence of tool geometry on drilling temperature, thrust force, and hole-making quality are analyzed. The effect of machining-induced damage on the tensile properties of CF/PEEK composites with machined hole are investigated. The strain distributions around the holes were measured using digital image correlation (DIC). The results indicate that PEEK is softened by heat, the matrix is plastically deformed, and the edge burrs of the hole are curled and agglomerated. The best hole-making quality is obtained by brad drill. Compared to the tensile strength of undrilled laminates, the tensile strength of the laminates drilled with brad, dagger and twist drills decreases by 51.47%, 53.99% and 56.09%, respectively. The strain distribution of open-hole laminates with different machining-induced damage shows obvious difference. The fracture mode of matrix cracking, fiber splitting, delamination, fiber pull-out and debonding are mainly observed. The research results in this paper can provide reference for the optimization of CF/PEEK composites drilling process.

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Experimental study on drilling process of a newly developed CFRP/Al/CFRP co-cured material

Cited by 12 publications

References 27 publications

Characterization of nanocomposite tetrahedral amorphous carbon coated drill bits for improved drilled-hole quality in carbon fiber-reinforced polymer/Al7075-T6 stacks

Characterization of nanocomposite tetrahedral amorphous carbon coated drill bits for improved drilled-hole quality in carbon fiber-reinforced polymer/Al7075-T6 stacks

A comparative study of hole integrity performance in composite‐metal stacks using coated and uncoated tungsten carbide drill bits

Investigation of tensile property and strain distribution of drilled carbon fiber reinforced polyetheretherkrtone composites

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