Hole exit damage and tool wear during the drilling of CFRP with a double-point angle drill

Li, Pengnan; Qiu, Xinyi; Li, Changping; Niu, Qiulin; Chen, Anhua; Ko, Tae Jo

doi:10.1007/s12206-019-0436-5

Cited by 14 publications

(5 citation statements)

References 27 publications

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“…The tool must travel deeper axially to allow for the remainder of the diameter to be machined. This results in the CD856 double-point angle design experiencing a lower thrust force and agrees well with thrust profiles determined in the research done by Li et al, who determined lower thrust and improved hole quality in comparison to standard twist drill geometries [ 54 ].…”

Section: Resultssupporting

confidence: 90%

3D Finite Element Model on Drilling of CFRP with Numerical Optimization and Experimental Validation

Hale

2021

Materials

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When drilling Carbon Fibre-Reinforced Plastic (CFRP) materials, achieving acceptable hole quality is challenging while balancing productivity and tool wear. Numerical models are important tools for the optimization of drilling CFRP materials in terms of material removal rate and hole quality. In this research, a macro-Finite Element (FE) model was developed to accurately predict the effect of drill tip geometry on hole entry and exit quality. The macro-mechanical material model was developed treating the Fiber-Reinforced Plastic (FRP) as an Equivalent Homogeneous Material (EHM). To reduce computational time, a numerical analysis was performed to investigate the influence of mass scaling, bulk viscosity, friction, strain rate strengthening, and cohesive surface modelling. A consideration must be made to minimize the dynamic effects in the FE prediction. The experimental work was carried out to investigate the effect of drill tip geometry on drilling forces and hole quality and to validate the FE results. The geometry of the drills used were either double-point angle or a “candle-stick” profile. The 3D drilling model accurately predicts the thrust force and hole quality generated by the two different drills. The results highlight the improvement in predicted results with the inclusion of cohesive surface modelling. The force signature profiles between the simulated and experimental results were similar. Furthermore, the difference between the predicted thrust force and those measured were less than 9%. When drilling with a double-angle drill tip, the inter-ply damage was reduced. This trend was observed in FE prediction.

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Section: Resultssupporting

confidence: 90%

3D Finite Element Model on Drilling of CFRP with Numerical Optimization and Experimental Validation

Hale

2021

Materials

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“…34 In addition, a double-pointed angle drill has less impact on the CFRP drilling hole wall and drill-exit damage. 44 However, compared with the above tools, the modified drill bit with clip-edges structure has smaller thrust force (about 45 N, the others are 70–160 N), a longer tool life, and does not need to change the drilling parameters and equipment. In summary, the modified one-shot drill bit has many advantages.…”

Section: Experimental Validationmentioning

confidence: 99%

Drill bit with clip-edges based on the force control model for reducing the CFRP damage

Hao

Wang

Zhao

et al. 2020

Journal of Reinforced Plastics and Composites

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Carbon fiber reinforced plastic composites are popular in the aviation industry, and it is inevitable to drill holes within strict damage tolerances during assembly. However, drilling damages often occur at the drill-exit of carbon fiber reinforced plastic for lacking back support. This paper aims to study the drilling damages formation of carbon fiber reinforced plastic, and further proposes a novel drill structure for reducing the damages. According to the damage formation of drill-exit fibers, the mathematical model is established to analyze the tool-fibers cutting process and fiber deflection. Then based on the cutting model, the multi-edge control force cutting method is proposed, and it is an effective method to cut off fibers with deflection control and damage reduction. In order to carry out the cutting effect, a novel clip-edges drill structure is proposed. The geometric analysis of the novel structure reveals that the structure can cut the fibers from both sides and reduce fiber resin cracking. Finally, comparative experiments are carried out in drilling carbon fiber reinforced plastic, and the novel drill bit with clip-edges drill structure can reduce drilling exit damage and obtain more high-quality holes.

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“…However, the diamond bit had broken, fallen off and adhered to wear after drilling four 7mm thick holes. The above results show that there are problems such as poor quality of hole wall, easy wear of tool, easy edge chipping at hole entrance, ber cracking and delamination in carbon ceramic drilling [11][12][13][14]. Wang et al [15] conducted a comparative test on the hole-making quality and cutting temperature of C/E composite materials by drilling and helical milling under the same cutting speed and processing e ciency.…”

Section: Introductionmentioning

confidence: 99%

Study on removal mechanism and surface quality in helical grinding 2.5D-Cf/SiC composites

Zhou,

Chen,

Liu

et al. 2024

Preprint

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Carbon fiber reinforced ceramic matrix composites have excellent heat resistance and wear resistance, making them extensively utilized in the aviation and aerospace industries. However, processing carbon ceramics is challenging due to the inherent difficulty. Traditional hole-making methods often result in issues such as delamination and tearing during the processing of carbon ceramics. Helical grinding has emerged as a novel processing technology that shows promise for difficult materials like carbon ceramics. To address the lack of clarity regarding the removal mechanism and formation mechanism of material damage during helical grinding of carbon ceramic materials. Firstly, this study models the trajectory and maximum undeformed chip thickness for single abrasive. Subsequently, analyzes the influence of fiber anisotropy on the removal mechanism during helical grinding of carbon ceramics. The study also investigates the mechanisms behind exit damage occurring during carbon ceramic helical grinding processes. Finally, examines helical grinding technological parameters affect surface quality by analyzing their impact on undeformed chip thickness. The results indicate that matrix occurs brittle fracture during helical grinding. Four typical removal mechanism emerge for different fiber angles: debonding is predominant at 0°; fiber fracture occurs at 45°; fiber shear occurred at 90°; fiber pull out occurred at 135°. Hole exit damage is influenced by fiber direction with minimal damage observed when shear fracture occurs at angles 45° and 90° while burrs phenomenon and tear phenomenon are prevalent at angles 0°and 135° respectively. By increasing orbital rotation speed and spindle speed or decreasing feed pitch, surface quality improved. Grinding parameters significantly affect surface quality through changing undeformed chip thickness and surface residual height.

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Hole exit damage and tool wear during the drilling of CFRP with a double-point angle drill

Cited by 14 publications

References 27 publications

3D Finite Element Model on Drilling of CFRP with Numerical Optimization and Experimental Validation

3D Finite Element Model on Drilling of CFRP with Numerical Optimization and Experimental Validation

Drill bit with clip-edges based on the force control model for reducing the CFRP damage

Study on removal mechanism and surface quality in helical grinding 2.5D-Cf/SiC composites

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