Recent Developments and Challenges on Machining of Carbon Fiber Reinforced Polymer Composite Laminates

Seo, Jung Hun; Kim, Do Young; Kim, Dong Chan; Park, Hyung Wook

doi:10.1007/s12541-021-00596-w

Cited by 31 publications

(11 citation statements)

References 131 publications

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“…In CFRP/metal stack drilling processes, especially when the metallic panel is titanium, minimum quantity lubrication (MQL) can be used to limit the adhesion of metal on the cutting edge, delay tool wear, and reduce the high temperatures produced during Ti drilling. However, Seo et al [ 37 ] indicated that MQL machining induced an increase in cutting force, and thus delamination, due to the reduced softening of the material induced by the reduced cutting temperatures. Fernández-Pérez et al [ 38 ] investigated the influence of the MQL level on the hole quality, tool wear, and power consumption during the drilling of Ti/CFRP/Ti stacks with a diamond-coated carbide drill bit of 7.6 mm in diameter.…”

Section: Methodsmentioning

confidence: 99%

Multi-Objective Optimization in Single-Shot Drilling of CFRP/Al Stacks Using Customized Twist Drill

Hassan

Abdullah

Franz³

2022

Materials

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In recent years, the use of CFRP with titanium and/or aluminum to form materials for stacking has gained popularity for aircraft construction. In practice, single-shot drilling is used to create perfectly aligned holes for the composite-metal stack. Usually, standard twist drills, which are commonly available from tool suppliers, are used for practical reasons. However, existing twist drill bits exhibit rapid wear upon the drilling of composite-metal stack layers in single shot, due to the widely contrasting properties of the composite-metal stack, which causes poor surface quality. The stringent quality requirements for aircraft component manufacturing demands frequent drill bit replacement and thus incurs additional costs, a concern still unresolved for aircraft component manufacturers. Owing to highly contrasting properties of a composite-metal stack, it is obvious that standard twist drill cannot fulfil the rigorous drilling requirements, as it is pushed to the limit for the fabrication of high-quality, defect-free holes. In this work, customised twist drills of a tungsten carbide (WC) material with different geometric features were specially fabricated and tested. Twenty drill bits with customised geometries of varying chisel edge angle (30–45°), primary clearance angle (6–8°), and point angle (130–140°) were fabricated. The stacked-up materials used in this study was CFRP and aluminum alloy 7075-T6 (Al7075-T6) with a total thickness of 3.587 mm. This study aims to investigate the effect of twist drill geometry on hole quality using drilling thrust force signature as indicator. All drilling experiments were performed at spindle speed of 2600 rev/min and feed rate of 0.05 mm/rev. Design of experiments utilising response surface methodology (RSM) method was used to construct the experimental array. Analysis of variance (ANOVA) was used to study the effect of parameters and their significance to the thrust force and thus the hole quality. The study shows that the most significant parameter affecting the drilling thrust force and hole surface roughness is primary clearance angle, followed by chisel edge angle. Correlation models of CFRP thrust force (Y1), AL7075-T6 thrust force (Y2), CFRP hole surface roughness (Y3), AL7075-T6 hole surface roughness (Y4) as a function of the tool geometry were established. The results indicated that the proposed correlation models could be used to predict the performance indicators within the limit of factors investigated. The optimum twist drill geometry was established at 45° of chisel edge angle, 7° of primary clearance angle, and 130° of point angle for the drilling of CFRP/AL7075-T6 stack material in a single-shot process. The error between the predicted and actual experiment values was between 6.64% and 8.17% for the optimum drill geometry. The results from this work contribute new knowledge to drilling thrust force signature and hole quality in the single-shot drilling of composite-metal stacks and, specifically, could be used as a practical guideline for the single-shot drilling of CFRP/AL7075-T6 stack for aircraft manufacturing.

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Section: Methodsmentioning

confidence: 99%

Multi-Objective Optimization in Single-Shot Drilling of CFRP/Al Stacks Using Customized Twist Drill

Hassan

Abdullah

Franz³

2022

Materials

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“…The strong commitment of world organizations in the field of safeguarding the planet has directed the research of these materials toward production processes with a lower environmental impact and a strong propensity to recycle the polymeric part [ 8 ]. The development of eco-sustainable composites has involved the study of glass/polymer [ 9 ], carbon/polymer [ 10 ], metal/polymer [ 11 ], polymer/polymer [ 12 ], ceramic/polymer [ 13 ], and concrete/polymer [ 14 ] interactions for the optimization of the final mechanical properties and the inclusion of these products in the perspective of environmental and economic circularity.…”

Section: Introductionmentioning

confidence: 99%

“…The strong commitment of world organizations in the field of safeguarding the planet has directed the research of these materials toward production processes with a lower environmental impact and a strong propensity to recycle the polymeric part [8]. The development of eco-sustainable composites has involved the study of glass/polymer [9], carbon/polymer [10], metal/pol- Nevertheless, one of the most effective solutions lies precisely in their production, in order to move toward eco-sustainable and circular composites. The strong commitment of world organizations in the field of safeguarding the planet has directed the research of these materials toward production processes with a lower environmental impact and a strong propensity to recycle the polymeric part [8].…”

Section: Introductionmentioning

confidence: 99%

Different Production Processes for Thermoplastic Composite Materials: Sustainability versus Mechanical Properties and Processes Parameter

2023

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Up to now, fiber-reinforced composites with thermoplastic matrix have seen limited fields of use in the structural scope due to their high viscosity in the molten state, which results in poor impregnability of the reinforcement, leading to mechanical properties of the finished product that are not comparable to those of thermosets. Although the latter still dominate the various sectors of automotive, aerospace, transportation and construction, new applications involving the production of thermoplastic composites are growing rapidly, offering new approaches to the solution of this problem. The aim of this work is to study and evaluate the state of the art on the manufacturing processes of thermoplastic matrix composite, analyzing the parameters that come into play and that most influence the process and material performance. The advantages of film stacking and powder impregnation techniques are contrasted by the versatility of hybrid fabrics and, at the same time, parameters such as pressure and temperature must be carefully considered. A description of different thermoplastic composite processes such as powder impregnation, film stacking molding, hybrid woven fabric, hybrid yarn and products follows, which represent the current possibilities to move from a thermosetting matrix composite to a thermoplastic one, upon which the concept of sustainability is based. This article wants to present an overview of research that has been done in manufacturing thermoplastic reinforced composites and will serve as a baseline and aid for further research and development efforts.

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“…The use of composite materials is rapidly expanding in many industrial sectors thanks to their ability to combine different properties and, thus, become extremely versatile. In recent decades, the development of eco-sustainable composites has involved the study of glass/polymer [1], carbon/polymer [2], metal/polymer [3], polymer/polymer [4], ceramic/polymer [5], and concrete/polymer [6] interactions for the optimization of the final mechanical properties and the inclusion of these products in the perspective of environmental and economic circularity.…”

Section: Introductionmentioning

confidence: 99%

Thermoplastic Composite Materials Approach for More Circular Components: From Monomer to In Situ Polymerization, a Review

et al. 2022

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To move toward eco-sustainable and circular composites, one of the most effective solutions is to create thermoplastic composites. The strong commitment of world organizations in the field of safeguarding the planet has directed the research of these materials toward production processes with a lower environmental impact and a strong propensity to recycle the polymeric part. Under its chemical properties, Nylon 6 is the polymer that best satisfies this specific trade-off. The most common production processes that use a thermosetting matrix are described. Subsequently, the work aimed at investigating the use of thermoplastics in the same processes to obtain comparable performances with the materials that are currently used. Particular attention was given to the in situ anionic polymerization process of Nylon 6, starting from the ε-caprolactam monomer. The dependencies of the process parameters, such as temperature, time, pressure, humidity, and concentration of initiators and activators, were therefore investigated with reference to the vacuum infusion technique, currently optimized only to produce thermosetting matrix composites, but promising for the realization of thermoplastic matrix composite; this is the reason why we chose to focus our attention on the vacuum infusion. Finally, three production processes of the polymeric matrix and glass fiber composites were compared in terms of carbon footprint and cumulative energy demand (CED) through life-cycle assessment (LCA).

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Recent Developments and Challenges on Machining of Carbon Fiber Reinforced Polymer Composite Laminates

Cited by 31 publications

References 131 publications

Multi-Objective Optimization in Single-Shot Drilling of CFRP/Al Stacks Using Customized Twist Drill

Multi-Objective Optimization in Single-Shot Drilling of CFRP/Al Stacks Using Customized Twist Drill

Different Production Processes for Thermoplastic Composite Materials: Sustainability versus Mechanical Properties and Processes Parameter

Thermoplastic Composite Materials Approach for More Circular Components: From Monomer to In Situ Polymerization, a Review

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