Study on Tool Wear and Chip Formation During Drilling Carbon Fiber Reinforced Polymer (CFRP)/Titanium Alloy (Ti6Al4V) Stacks

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

doi:10.1016/j.proeng.2013.09.133

Cited by 94 publications

(32 citation statements)

References 7 publications

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“…To this aim, great motivations have been exploited in order to address deeply the topics, and a large amount of scientific work has been undertaken within the past few decades. Table 1 summarizes the key experimental studies that have been conducted in the open literature concerning FRP/Ti drilling [1,2,9,[38][39][40][41][42][43][44][45][46][47][48][49][50][51][52][53].…”

Section: Frp/ti Assemblymentioning

confidence: 99%

“…Results showed that the two-flute drill bit with higher helix angle generated smallest cutting force and lowest cutting temperature as compared to other used drills due to its large flute volume for chip evacuation and heat dissipation. SenthilKumar et al [49] examined the effects of point angle on tool performance when drilling of CFRP/Ti stack by using 118° and 130° point angle drills. It was concluded that the drills with higher point angle (130°) outperformed those with lower point angle (118°) from the evaluation of tool wear and chip evacuation.…”

Section: Cutting Toolmentioning

confidence: 99%

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Recent advances in drilling hybrid FRP/Ti composite: A state-of-the-art review

Mkaddem

Mansori

2016

Composite Structures

203

109

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Hybrid composite stack, especially FRP/Ti assembly, is considered as an innovative structural configuration for manufacturing the key load-bearing components favoring energy saving in the aerospace industry. Several applications require mechanical drilling for finishing hybrid composite structures. The drilling operation of hybrid FRP/Ti composite, however, represents the most challenging task in modern manufacturing sectors due to the disparate natures of each constituent involved and the complexity to control tool-material interfaces during one single cutting shot. Special issues may arise from the severe subsurface damage, excessive interface consumption, rapid tool wear, etc. In this paper, a rigorous review concerning the state-of-the-art results and advances on drilling solutions of hybrid FRP/Ti composite was presented by referring to the wide comparisons among literature analyzes. The multiple aspects of cutting responses and physical phenomena generated when drilling these materials were precisely addressed. A special focus was made on the material removal modes and tool wear mechanisms dominating the bi-material interface consumption (BIC) with respect of investigating strategies used. The key conclusions from the literature review were drawn to point out the potential solutions and limitations to be necessarily overcome for reaching both (i) enhanced control of drilling operation, and (ii) better finish quality of FRP/Ti parts.

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Section: Frp/ti Assemblymentioning

confidence: 99%

Section: Cutting Toolmentioning

confidence: 99%

Recent advances in drilling hybrid FRP/Ti composite: A state-of-the-art review

Mkaddem

Mansori

2016

Composite Structures

203

109

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“…In fact, in the aeronautical field, the percentage of pieces rejected because of delamination ascends to 60 % [1]. Furthermore, CFRP is a highly abrasive material and depending on the fiber orientation, it can cause a severe tool wear, which is accelerated when using high cutting speeds [2][3][4]. Different drill designs and coatings are commonly employed for avoiding the tool wear [1,5].…”

Section: Introductionmentioning

confidence: 99%

An experimental study on abrasive waterjet cutting of CFRP/Ti6Al4V stacks for drilling operations

Alberdi

Artaza

Suárez

et al. 2015

Int J Adv Manuf Technol

114

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In the present study, CFRP/Ti6Al4V stacks were machined with abrasive water jet using different process parameters in order evaluate the viability of AWJ industrial application as a substitute of conventional drilling. The effect of the stack configuration, the traverse feed rate, the cutting tool (combination of orifice and focusing tube diameter and abrasive mass flow rate), and the pressure over the kerf profile, taper angle, and surface roughness has been analyzed through an ANOVA analysis and related to the physical parameters of the AWJ process. As a result, a positive taper angle is observed in Ti6Al4V while a negative is observed in CFRP in almost all cutting conditions. This leads to obtain an X-type or barrel-type kerf profile depending on the stack configuration. In addition, the surface roughness can be as low as 6.5 μm in both CFRP and Ti6Al4V materials at 95 mm/min when CFRP/Ti6Al4V configuration is used.

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“…High cutting speed of CFRP requires high strength and high stiffness [32,33]. Therefore cemented carbide is more suitable and this work selects the cemented carbide K40UF as the tool body material.…”

Section: Materials Of the Staggered Pcd End Millmentioning

confidence: 99%

Development of a Staggered PCD End Mill for Carbon Fiber Reinforced Plastic

et al. 2017

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This work presents a PCD (polycrystalline diamond) end mill with a new staggered structure for the milling of CFRP (carbon fiber reinforced plastic). The magnitude and direction of cutting force is decreased and changed by side-edge re-configuration of the structure. The flute and insert pocket of the staggered PCD end mill are designed considering the tool's stiffness and welding process. The milling process and machining defects of the staggered PCD end mill are analyzed, and the structural parameters of the staggered PCD end mill are determined. The staggered PCD end mill is fabricated by the process of wire cutting, NC (Numerical Control) machining, high-frequency induction brazing, welding, grinding and passivation. Milling tests of multidirectional CFRP with the staggered PCD end mill is conducted on CNC (Computerized Numerical Control) milling machine. The milling force is measured by a dynamometer. A range analysis of the numerical results of milling force is conducted after milling test, and the influence of milling parameters on milling force is analyzed. A regression model of the milling force is built and verified by experiment. The effects of fiber cutting angle on milling force are obtained through milling CFRP with different fiber orientation angles.

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Study on Tool Wear and Chip Formation During Drilling Carbon Fiber Reinforced Polymer (CFRP)/Titanium Alloy (Ti6Al4V) Stacks

Cited by 94 publications

References 7 publications

Recent advances in drilling hybrid FRP/Ti composite: A state-of-the-art review

Recent advances in drilling hybrid FRP/Ti composite: A state-of-the-art review

An experimental study on abrasive waterjet cutting of CFRP/Ti6Al4V stacks for drilling operations

Development of a Staggered PCD End Mill for Carbon Fiber Reinforced Plastic

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