Temperature analysis in fiber metal laminates drilling: Experimental and numerical results

Parodo, Gianluca; Rubino, Felice; Sorrentino, Luca; Turchetta, Sandro

doi:10.1002/pc.26864

Cited by 15 publications

(8 citation statements)

References 45 publications

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“…Sorrentino et al [ 58 ] reported that high-speed cutting and low-feed machining allow a significant reduction of the F z component of the cutting force, which is responsible for any delamination/detachment issues in the material. Additionally, a decrease in spindle speed and high feed rate in the drilling of GLARE composite causes tool tip temperature, which causes problems of higher cutting force and critical resin temperature in polymeric composite materials [ 59 , 60 ].…”

Section: Resultsmentioning

confidence: 99%

Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al–PE) Using Taguchi Orthogonal Array Design

et al. 2023

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Aluminum Matrix Composite (AMC) represents an innovative class of materials that is extensively utilized in industries such as automotive, defense, aerospace, structural engineering, sports, and electronics. This study investigates the thrust force, exit burr formation, changes in the micro-tool, and drilled hole diameters during the micro-drilling of an aluminum-polyethylene composite panel (Al–PE). The panel consists of 3501 series aluminum skin materials bonded to a polyethylene (PE) core. Micro-drilling test parameters were designed using Taguchi’s L16 (42 23) orthogonal array. Tests were conducted with five control parameters: cutting speed with four levels (10 m/min, 20 m/min, 30 m/min, 40 m/min), feed rate with four levels (0.5 µm/rev, 1 µm/rev, 2 µm/rev, 4 µm/rev), the tool diameter with two levels (0.7 mm, 1 mm), and tool point angle with two levels (100°, 140°) using both AlTiN-coated and uncoated drills. The maximum thrust force (Fz), maximum burr height, and changes in both the drill tool and hole diameters were measured for analysis of variance (ANOVA). The results showed that, in terms of impact on Fz, tool point angle had the highest positive influence (64.54%) on the micro-drill at the entrance of composite (upper aluminum plate). The cutting speed had the highest positive influence (45.32%) on the tool in the core layer (PE core layer). The tool point angle also had the highest positive influence (68.95%) on the micro-drill at the lower layer of the composite (the lower aluminum plate). There was noticeable chip adhesion on the major cutting edge and nose area under micro-drilling conditions with higher thrust forces and burr height. The AlTiN coating had a positive effect on tool wear and hole diameter deviations, but it adversely affected the burr height.

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Section: Resultsmentioning

confidence: 99%

Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al–PE) Using Taguchi Orthogonal Array Design

et al. 2023

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“…In most of the literature AA 2024-T3 has been used for the fabrication of FMLs. 7,[32][33][34][35][36][37][38][39] Few of the researchers have also used other grades of aluminum alloys such as AA 1050, [40][41][42] AA 1060-H12, 43 AA 1200-H14, 44 AA 2024-O, 45 AA 5005, 46 AA 5052-O, 47 AA 5052-H32, [48][49][50] AA 6061-T6, 17,29,51,52 AA 6063-T6, 53 and AA 7075-T6. 52,54,55 Limited amount of work has been conducted on the Magnesium alloy, 56,57 Titanium, 45 and Steel.…”

Section: Research Gap Addressed In the Papermentioning

confidence: 99%

“…On a component level application, Wang et al 31 established a multi‐objective integrated optimization framework considering for the fabrication of a tapered rim composed of CFRP rim and aluminum alloy spoke. In most of the literature AA 2024‐T3 has been used for the fabrication of FMLs 7,32–39 . Few of the researchers have also used other grades of aluminum alloys such as AA 1050, 40–42 AA 1060‐H12, 43 AA 1200‐H14, 44 AA 2024‐O, 45 AA 5005, 46 AA 5052‐O, 47 AA 5052‐H32, 48–50 AA 6061‐T6, 17,29,51,52 AA 6063‐T6, 53 and AA 7075‐T6 52,54,55 .…”

Section: Research Gap Addressed In the Papermentioning

confidence: 99%

High‐velocity ballistic response of AA 1100‐H14 based carbon‐fiber metal laminates: An experimental investigation

Jamsheed,

Rashid,

Velmurugan

2023

Polymer Composites

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A detailed experimental investigation was carried out for the high‐velocity ballistic response of AA 1100‐H14 based carbon‐fiber metal laminates (FMLs). FMLs with different metal volume fractions and the same thickness of carbon‐epoxy fiber laminates were tested to examine the surface and internal damage. The ballistic performance parameters, namely % escalation in absorbed energy, specific energy absorbed, ballistic limit, specific perforation energy, first cracking energy, and global deformation profile, were studied and a comparison was drawn with pure carbons fiber reinforced epoxy composite laminates. Despite having greater thickness, pure carbon fiber‐reinforced epoxy composite laminates absorbed less impact energy than FMLs and failed catastrophically. For FMLs, the % escalation in the absorbed energy and the specific energy absorption kept increasing with the increasing impact velocity until the onset of perforation. Once the perforation started, both these parameters showed a decreasing trend. Thick FMLs absorbed a good amount of energy, leading to projectile recoil suffering minimal damage. The ballistic velocity, specific perforation energy, and first cracking energy on the front and rear face of FMLs layers showed an increasing trend. The minimum for the thinner and maximum for the thicker FMLs attributed to the large thickness and more metal volume fraction. Contrary to the large deformation of the impacting points, pure carbon fiber‐reinforced epoxy composite laminates showed very minimal deformation as compared to FMLs. The brittle nature of the epoxy resin resisted the deformation to a large extent leading to less energy absorption.Highlights High‐velocity ballistic response of AA 1100‐H14 based carbon‐FMLs was investigated. Ballistic performance parameters of FMLs were studied and was compared with carbons fiber reinforced composite laminates. The ballistic limit of FMLs showed a direct dependence its thickness and metal volume fraction. In the absence of any metallic layer, pure carbons fiber reinforced composite laminates absorbed less impact energy.

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“…The thermophysical properties of fiber-reinforced polymers result in high temperatures at the tool tip during the drilling process. [31][32][33] These materials have relatively low thermal conductivity and heat capacity compared to metal matrix materials, causing an imbalance in the energy transfer between the tool and workpiece. Additionally, their low thermal expansion coefficient leads to accuracy errors during machining.…”

Section: Introductionmentioning

confidence: 99%

“…The dry drilling process poses a risk of inducing thermal damage because of elevated process temperatures. The thermophysical properties of fiber‐reinforced polymers result in high temperatures at the tool tip during the drilling process 31–33 . These materials have relatively low thermal conductivity and heat capacity compared to metal matrix materials, causing an imbalance in the energy transfer between the tool and workpiece.…”

Section: Introductionmentioning

confidence: 99%

Micro drilling characterization of the carbon and carbon–aramid (hybrid) composites

Sen,

Eryilmaz,

Bakir

2024

Polymer Composites

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In this study, micro‐drilling tests were carried out on composite laminates reinforced with hybrid (aramid‐carbon) and carbon fibers. Thrust force, hole quality, tool wear, and temperature parameters were measured and assessed following each drilling test. The quality of holes includes circularity, overcut, hole damage factor (HDF), and taper ratio. Micro‐drilling was performed on a CNC milling machine using 0.6 mm drill diameter, 7500 rpm, and 0.5 mm/min feed parameters. The plates are 3.05 mm (carbon fiber) and 3.45 mm (hybrid) thick. According to the results, the maximum thrust force (29.8 N) was measured in the hybrid composite due to the high fracture toughness of the aramid. In addition, it was determined that the thrust force and drill wear were related. The increase in thrust force during drilling caused an increase in drill wear values. While the average wear of the drill in carbon composite was 0.013 mm, the average wear of the drill in hybrid composite was 0.021 mm. Thrust force and tool temperatures were found to have a similar trend. The highest tool temperature was measured as 86.7°C in the hybrid composite. Hole quality results showed that drilling in carbon composite was more successful than in hybrid composite. Holes drilled in carbon composite have lower values for overcut (0.017 mm), HDF (1.028), and taper ratio (0.008). It has been understood that hole quality depends on thrust force and damage formation.Highlights Carbon and hybrid (carbon‐aramid) composites were produced with a vacuum infusion process (VIP). Micro‐drilling of composites was investigated focusing on thrust force, tool temperature, and hole quality. Hybrid composites exhibited greater thrust forces due to their higher toughness compared to carbon composites. Hybrid composites showed higher maximum tool temperatures compared to carbon composites. The carbon composites exhibited better hole quality compared to the hybrid composites.

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Temperature analysis in fiber metal laminates drilling: Experimental and numerical results

Cited by 15 publications

References 45 publications

Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al–PE) Using Taguchi Orthogonal Array Design

Optimization of Micro-Drilling of Laminated Aluminum Composite Panel (Al–PE) Using Taguchi Orthogonal Array Design

High‐velocity ballistic response of AA 1100‐H14 based carbon‐fiber metal laminates: An experimental investigation

Micro drilling characterization of the carbon and carbon–aramid (hybrid) composites

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