Study of the one-shot drilling of CFRP/Ti6Al4V stacks with a double tip angle cutting-tool geometry

Bañon, Fermin; Sambruno, Alejandro; Batista, M.; Fernandez-Vidal, Sergio; Salguero, Jorge

doi:10.1063/1.5112618

Cited by 5 publications

(4 citation statements)

References 11 publications

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“…Titanium alloys are used in a number of other industrial applications, including emission control, flue gas desulfurization, purified terepthalic acid (PTA) plants for polyester processing, pressure vessels, heat exchangers, and hydrometallurgical autoclaves. Each grade is customized to particular working conditions, with an emphasis on strength for various stresses, alloy quality for various corrosive agents, and ductility for various fabrication requirements [ 1 , 2 , 3 , 4 , 5 ]. Ti-6Al-4V (6% aluminum and 4% vanadium) is a titanium-based alloy that is widely used because of its high fatigue resistance and good corrosion resistance capacity.…”

Section: Introductionmentioning

confidence: 99%

Revealing the WEDM Process Parameters for the Machining of Pure and Heat-Treated Titanium (Ti-6Al-4V) Alloy

et al. 2021

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Ti-6Al-4V is an alloy that has a high strength-to-weight ratio. It is known as an alpha-beta titanium alloy with excellent corrosion resistance. This alloy has a wide range of applications, e.g., in the aerospace and biomedical industries. Examples of alpha stabilizers are aluminum, oxygen, nitrogen, and carbon, which are added to titanium. Examples of beta stabilizers are titanium–iron, titanium–chromium, and titanium–manganese. Despite the exceptional properties, the processing of this titanium alloy is challenging when using conventional methods as it is quite a hard and tough material. Nonconventional methods are required to create intricate and complex geometries, which are difficult with the traditional methods. The present study focused on machining Ti-6Al-4V using wire electrical discharge machining (WEDM) and conducting numerous experiments to establish the machining parameters. The optimal setting of the machining parameters was predicted using a multiresponse optimization technique. Experiments were planned using the response surface methodology (RSM) technique and analysis of variance (ANOVA) was used to determine the significance and contribution of the input parameters to changes in the output characteristics (cutting speed and surface roughness). The cutting speed obtained during the processing of the annealed titanium alloy using WEDM was quite large as compared to the cutting speed obtained in the case of processing the pure, quenched, and hardened titanium alloys using WEDM. The maximum cutting speed obtained while processing the annealed titanium alloy was 1.75 mm/min.

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Section: Introductionmentioning

confidence: 99%

Revealing the WEDM Process Parameters for the Machining of Pure and Heat-Treated Titanium (Ti-6Al-4V) Alloy

et al. 2021

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“…The main metallic alloys used in the form of a hybrid structure are light alloys, aluminum [1,68] or titanium, especially the alloy Ti6Al4V [13,69], in combination with a polymeric composite material.…”

Section: Surface Quality In the Awjm Of Hybrid Structuresmentioning

confidence: 99%

“…As an example of previously described is the performance of drilling operations of hybrid structures in the aeronautical sector. The most commonly used configurations are "CFRP-Aluminum" [1,12] and "CFRP-Titanium" [13][14][15]. The aeronautical sector, therefore, seeks to reduce time and costs by machining in a single step structural elements to be assembled by means of mechanical joining operations through rivets [1,16].…”

Section: Introductionmentioning

confidence: 99%

A Review on the Abrasive Water-Jet Machining of Metal–Carbon Fiber Hybrid Materials

Bañon

Sambruno

González-Rovira

et al. 2021

Metals

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The bonding of metallic alloys and composite materials in the form of a hybrid structure is a line of great interest for the current industry. The different machinability of both materials requires a specific machining process. Abrasive water-jet machining (AWJM) is an excellent technology for the simultaneous machining of both materials. However, defects at the micro and macro-geometric level have been detected in several scientific articles. In this review, a detailed study of the two main defects in metals, composite materials and hybrid structures has been developed. The conclusions of several scientific articles have been exposed for a better understanding of the topic in articles between 1984 and 2020. The influence of the cutting parameters on the reduction in kinetic energy of the water jet and the order of stacking of the materials in the hybrid structure is the main objective in order to minimize these defects. Cutting parameter optimization studies, predictive model proposals, process-associated defects and evaluation methodologies have been discussed. The aim of this article is to set a solid background on AWJM machining in hybrid structures and on the influence of cutting parameters on generated defects and machining strategies to obtain the best results at a macro and micro-geometric level.

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“…Various factors were reported to affect the hole quality parameters in CFRP/Ti alloy stacks, including drill bit wear rate [ 6 , 25 , 26 , 27 , 28 , 29 ], cutting tool coating [ 4 , 15 , 22 , 26 , 30 , 31 , 32 ], cutting parameters [ 10 , 11 , 14 , 33 , 34 ], drill bit geometry [ 8 , 21 , 35 , 36 ], dynamic characteristics of CFRP [ 37 ], drilling strategies, and techniques, namely one-shot drilling of the stack [ 10 , 11 , 14 , 22 , 33 , 35 , 38 , 39 , 40 , 41 ], stepped bit geometry drilling [ 8 , 21 ], pilot hole drilling [ 42 ], cryogenic drilling [ 43 , 44 ], minimal quantity lubrication (MQL) [ 29 , 45 ], helical milling [ 9 , 46 ], and drilling with core drill [ 47 ]. In such a way, it can be summarized that one-shot drilling of CFRP/Ti alloy stacks is still a mainstream technology of manufacturing holes studies; we concluded that the most promising factors to improve the hole quality are the cutting parameters of the one-shot drilling strategy.…”

Section: Introductionmentioning

confidence: 99%

Application of ANN for Analysis of Hole Accuracy and Drilling Temperature When Drilling CFRP/Ti Alloy Stacks

et al. 2022

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Drilling of Carbon Fiber-Reinforced Plastic/Titanium alloy (CFRP/Ti) stacks represents one of the most widely used machining methods for making holes to fasten assemblies in civil aircraft. However, poor machinability of CFRP/Ti stacks in combination with the inhomogeneous behavior of CFRP and Ti alloy face manufacturing and scientific community with a problem of defining significant factors and conditions for ensuring hole quality in the CFRP/Ti alloy stacks. Herein, we investigate the effects of drilling parameters on drilling temperature and hole quality in CFRP/Ti alloy stacks by applying an artificial neuron network (ANN). We varied cutting speed, feed rate, and time delay factors according to the factorial design L9 Taguchi orthogonal array and measured the drilling temperature, hole diameter, and out of roundness by using a thermocouple and coordinate measuring machine methods for ANN analysis. The results show that the drilling temperature was sensitive to the effect of stack material layer, cutting speed, and time delay factors. The hole diameter was mainly affected by feed, stack material layer, and time delay, while out of roundness was influenced by the time delay, stack material layer, and cutting speed. Overall, ANN can be used for the identification of the drilling parameters–hole quality relationship.

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Study of the one-shot drilling of CFRP/Ti6Al4V stacks with a double tip angle cutting-tool geometry

Cited by 5 publications

References 11 publications

Revealing the WEDM Process Parameters for the Machining of Pure and Heat-Treated Titanium (Ti-6Al-4V) Alloy

Revealing the WEDM Process Parameters for the Machining of Pure and Heat-Treated Titanium (Ti-6Al-4V) Alloy

A Review on the Abrasive Water-Jet Machining of Metal–Carbon Fiber Hybrid Materials

Application of ANN for Analysis of Hole Accuracy and Drilling Temperature When Drilling CFRP/Ti Alloy Stacks

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