Machining of CFRP/Ti6Al4V stacks under minimal quantity lubricating condition

Senthilkumar, M.; Prabukarthi, A.; Krishnaraj, V.

doi:10.1007/s12206-018-0731-6

Cited by 40 publications

(12 citation statements)

References 16 publications

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“…Minimum quantity lubricant (MQL) is a technology used to approach the tool/workpiece interface with a minimum amount of coolant medium to achieve the economic and environmental pro ts [28]. In terms of cutting temperature, tool life, and machining performance, the utilization of MQL showed a signi cant enhancement during the CD and LF-VAD process of CFRP/Ti6Al4V, as presented in [28,29]. The combination effect of LF-VAD and MQL coolant showed 42 % reduction on the cutting temperature with a long tool life.…”

Section: Introductionmentioning

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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Section: Introductionmentioning

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 experimental studies the most often measured physical quantities are thrust force ( F , N) [ 1 , 5 ], torque ( M c , Nmm) [ 1 , 5 ], cutting temperature (T, °C) [ 7 , 8 , 9 , 10 , 11 , 12 , 13 , 14 ], chip formation mechanism [ 14 , 15 ], and technical quantities such as flank wear [ 16 , 17 , 18 ] and tool life [ 19 ]. The abovementioned quantities are commonly used to explain the physical nature of cutting parameters [ 3 ], the tool geometry [ 20 , 21 ], and tool material, as well as the coolant application effect [ 7 , 22 , 23 , 24 ] on the response values. In an experimental study of Ti/CFRP/Al stack drilling, it was found that the feed rate (0.05–0.15 mm/r) had a significant impact on thrust force with percentage contribution ratios (PCR) of 40% in Ti, 31% in CFRP, and 20% in Al, as well as on the torque with PCR‘s of 72% in Ti and 24% in Al [ 3 ].…”

Section: Introductionmentioning

confidence: 99%

“…It was specified that the most significant factors that responded to delamination in CFRP are feed rate [ 19 , 25 , 26 ] and point angle [ 26 , 27 ]. However, the burr size in Ti alloy is mostly affected by the feed rate [ 28 ], tool material [ 29 ], and tool wear [ 17 , 18 ], and it could be reduced by using MQL [ 7 , 24 , 29 ], LN 2 [ 16 , 30 , 31 ], VAD [ 22 ] and UAD [ 10 , 23 ] techniques. According to Xu and Mansori [ 27 ], the surface roughness in CFRP when drilling CFRP/Ti stack is 3 times worse than when drilling only CFRP, which was explained by Titanium chip sliding in CFRP hole wall [ 29 ].…”

Section: Introductionmentioning

confidence: 99%

“…The study of Benezech et al [ 20 ] concerning CFRP/metal stack drilling, with a point angle variation (120−150°) and rake angle (10–40°), shows that the optimal drill geometry is 135° for the point angle and 30° for the rake angle because of short chip formation which decreases the wall integrity. One more significant factor which influences the hole diameter regardless of the feed rate is the parameter of the drill’s margin [ 24 ]. It was established that the triple margin drill could produce more accurate holes due to the reduction of vibrations because of increasing contact with the machined surface [ 32 ].…”

Section: Introductionmentioning

confidence: 99%

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Experimental Study of Drilling Temperature, Geometrical Errors and Thermal Expansion of Drill on Hole Accuracy When Drilling CFRP/Ti Alloy Stacks

et al. 2020

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The drilling of holes in CFRP/Ti (Carbon Fiber-Reinforced Plastic/Titanium alloy) alloy stacks is one of the frequently used mechanical operations during the manufacturing of fastening assemblies in temporary civil aircraft. A combination of inhomogeneous behavior and poor machinability of CFRP/Ti alloy stacks in one short drilling brought challenges to the manufacturing community. The impact of the drilling temperature and time delay factor under various cutting conditions on hole accuracy when machining CFRP/Ti alloy stacks is poorly studied. In this paper, the drilling temperature, the phenomenon of thermal expansion of the drill tool, and hole accuracy are investigated. An experimental study was carried out using thermocouples, the coordinate measuring machine method, and finite element analysis. The results showed that the time delay factor varied from 5 (s) to 120 (s), influences the thermal-dependent properties of CFRP, and leads to an increase in hole roundness. Additionally, the thermal expansion of the drill significantly contributes to the deviation of the hole diameter in Ti alloy.

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“…Senthilkumar et al [9] investigated the drilling performance of CFRP/Ti6Al4V stacks under minimum quantity lubrication technique. The study investigated three different tool geometries with two cutting tool materials such as K20 carbide and TiAlN-coated carbide using various flow rates of LRT 30 oil-based MQL.…”

Section: Introductionmentioning

confidence: 99%

Ecofriendly inclined drilling of carbon fiber-reinforced polymers (CFRP)

Pervaiz

Kannan

Huo

2020

Int J Adv Manuf Technol

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Key composite made aerostructures such as fuselage inner walls, flap support fairings, empennage ribs, and the vertical fin ribs are comprised of non-vertical inclined and radial holes that join with other key metallic and non-metallic structures. Carbon fiber reinforced plastics (CFRP) are also used in the aerospace, automotive, marine, and sports-related applications due to their superior properties such as high strength to weight ratio, better fatigue, and high stiffness. CFRP drilling operation is different than the homogenous materials as the cutting-edge interacts with fiber and matrix simultaneously. Flank face of the tool rubs on the workpiece material and develops high frictional contact due to the elastic recovery of broken fibers. Lubrication during CFRP cutting can reduce the friction involved at tool-workpiece interface to enhance cutting performance. Dry cutting, cryogenic machining, and minimum quantity lubrication (MQL)-based strategies are termed as ecofriendly cooling/lubrication methods when machining high performance materials. The abrasive nature of carbon fiber is responsible of producing cutting forces which leads to different types of imperfections such as delamination, uncut fiber, fiber breakout, and fiber pullout. The integrity of CFRP drilled hole especially at the entry and exit of the hole plays a significant role towards the overall service life. The presented paper aims to characterize the interrelationships between hole inclination, lubrication/cooling methods, tool coating, and drill geometry with inclined hole bore surface quality and integrity during drilling of CFRP laminates. In dry cutting, thrust forces were found 2.38 times higher in the 30° inclination when compared with the reference 90° conventional inclination angle. Compressed air provided lowest increase (1.46 times) in the thrust forces for 30° inclination.

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Machining of CFRP/Ti6Al4V stacks under minimal quantity lubricating condition

Cited by 40 publications

References 16 publications

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

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

Experimental Study of Drilling Temperature, Geometrical Errors and Thermal Expansion of Drill on Hole Accuracy When Drilling CFRP/Ti Alloy Stacks

Ecofriendly inclined drilling of carbon fiber-reinforced polymers (CFRP)

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