Abstract
Carbon fiber-reinforced plastics (CFRPs) have many excellent properties, such as lightless, high specific strength, and high corrosion resistance, and they have been extensively used in the aeronautics and astronautics. It is a challenge for studies on the defect-free drilling technology and the causes of drilling defects to the CFRP materials. The purpose of this study is to research the machining parameters and the stepped drill geometry effect on cutting force and hole wall damage with the test methods. Both a twist drill and three stepped drills were employed in drilling CFRP plates under the experimental conditions. The effects of both the processing parameters and the stepped drill structure (the ratio of the pilot section diameter to the sizing diameter section diameter (D1/D)) on thrust force and hole wall damage were investigated, and the damage mechanism of hole walls was revealed by analyzing the cross-section features of the hole wall. The results show that the maximum thrust force of T3 (D1/D = 0.5) is minimal, so T3 should be selected to reduce the risk of delamination. D1/D, feed rate, and spindle speed are the main factors that affect the size of the hole wall damage. In addition, a special cutting force Fspec is defined to explain the influence of tool structure and feed rate on hole wall damage.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Wang HW, Sun J, Li JF, Li WD (2014) Investigation on delamination morphology during drilling composite laminates. Int J Adv Manuf Technol 74:257–266
Chen LX, Zhang KF, Cheng H, Qi ZC, Meng QX (2017) A cutting force predicting model in orthogonal machining of unidirectional CFRP for entire range of fiber orientation. Int J Adv Manuf Technol 89:833–846
Mishra R, Malik J, Singh I, Davim JP (2010) Neural network approach for estimate the residual tensile strength after drilling in uni-directional glass fiber reinforced plastic laminates. Mater Des 31:2790–2795
Su F, Wang ZH, Yuan JT, Cheng Y (2014) Study of thrust forces and delamination in drilling carbon-reinforced plastics (CFRPs) using a tapered drill-reamer. Int J Adv Manuf Technol 80:1457–1469
Krishnaraj V, Prabukarthi A, Ramanathan A, Elanghovan N, Kumar MS, Zitoune R, Davim JP (2012) Optimization of machining parameters at high speed drilling of carbon fiber reinforced plastic (CFRP) laminates. Compos Part B Eng 43:1791–1799
Schulze V, Becke C, Weidenmann K, Dietrich S (2010) Machining strategies for hole making in composites with minimal workpiece damage by directing the process forces inwards. J Mater Process Technol 211:329–338
Lazar MB, Xirouchakis P (2011) Experimental analysis of drilling fiber rein-forced composites. Int J Mach Tools Manuf 51:937–946
Anand RS, Patra K, Stiner M (2014) Size effects in micro drilling of carbon fiber reinforced plastic composite. Prod Eng Res Dev 8:301–307
Lau WS, Yue TM, Lee TC, Lee WB (1995) Un-conventional machining of composite materials. J Mater Process Technol 48:199–205
Piquet R, Ferret B, Lachaud F, Swider P (2000) Experimental analysis of drilling damage in thin carbon/epoxy plate using special drills. Compos Part A Eng 31:1107–1115
Xu JY, An QL, Cai XJ, Chen M (2013) Drilling machinability evaluation on new developed high-strength T800S/250F CFRP laminates. Int J Precis Eng Manuf 14:1687–1696
Shyha IS, Aspinwall DK, Soo SL, Bradley S (2009) Drill geometry and operating effects when cutting small diameter holes in CFRP. Int J Mach Tools Manuf 49:1008–1014
Tsao CC, Hocheng H (2004) Taguchi analysis of delamination associated with various drill bits in drilling of composite material. Int J Mach Tools Manuf 44:1085–1090
Tsao CC, Hocheng H (2005) Effect of eccentricity of twist drill and candle stick drill on delamination in drilling composite materials. Int J Mach Tools Manuf 45:125–130
Bhatnagar N, Singh I, Nayak D (2004) Damage investigation in drilling of glass fiber reinforced plastic composite laminates. Mater Manuf Process 19:995–1007
Singh I, Bhatnagar N (2006) Drilling of uni-directional glass fiber reinforced plastic (UD-GFRP) composite laminates. Int J Adv Manuf Technol 26:870–876
Karpat Y, Değer B, Bahtiyar O (2012) Drilling thick fabric woven CFRP laminates with double point angle drills. J Mater Process Technol 212:2117–2127
Karpat Y, Değer B, Bahtiyar O (2014) Experimental evaluation of polycrystalline diamond tool geometries while drilling carbon fiber-reinforced plastics. Int J Adv Manuf Technol 71:1295–1307
Karpat Y, Bahtiyar O (2015) Tool geometry based prediction of critical thrust force while drilling carbon fiber reinforced polymers. Adv Manuf 3:300–308
Wang CY, Chen YH, An QL, Cai XJ, Ming WW, Chen M (2015) Drilling temperature and hole quality in drilling of CFRP/aluminum stacks using diamond coated drill. Int J Precis Eng Manuf 16:1689–1697
Durao LMP, Goncalves DJS, Tavares JMRS, de Albuquerque VHC, Aguiar Vieira A, Tomes Marques A (2010) Drilling tool geometry evaluation for reinforced composite laminates. Compos Struct 92:1545–1550
Abrao AM, Rubio JCC, Faria PE, Davim JP (2008) The effect of cutting tool geometry on thrust force and delamination when drilling glass fiber reinforced plastic composite. Mater Des 29:508–513
Rawat S, Attia H (2009) Characterization of the dry high speed drilling process of woven composites using machinability maps approach. CIRP Ann-Manuf Technol 58:105–108
Rawat S, Attia H (2009) Wear mechanisms and tool life management of WC-Co drills during dry high speed drilling ofwoven carbon fibre composites. Wear 267:1022–1030
El-Sonbaty I, Khashaba UA, Machaly T (2004) Factors affecting the machine-ability of GFR/epoxy composites. Compos Struct 63:329–338
Mohan NS, Ramachandra A, Kulkarni SM (2005) Machining of fiber- reinforced thermoplastics: influence of feed and drill size on thrust force and torque during drilling. J Reinforced Plast Compos 24:1247–1257
Teti R (2002) Machining of composite materials. CIRP Ann-Manuf Technol 51:611–634
Abhishek K, Datta S, Mahapatra SS (2015) Optimization of thrust, torque, entry, and exist delamination factor during drilling of CFRP composites. Int J Adv Manuf Technol 76:401–416
Tsao CC (2007) Effect of pilot hole on thrust force by saw drill. Int J Mach Tools Manuf 47:2172–2176
Tsao CC (2008) Prediction of thrust force of step drill in drilling composite material by Taguchi method and radial basis function network. Int J Adv Manuf Technol 36:11–18
Funding
The work is supported by the National Natural Science Foundation of China (No.51775184, No.51275168, No.51605161) and by the Hunan provincial Natural Science Foundation of China (No.2015JJ5028).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Qiu, X., Li, P., Niu, Q. et al. Influence of machining parameters and tool structure on cutting force and hole wall damage in drilling CFRP with stepped drills. Int J Adv Manuf Technol 97, 857–865 (2018). https://doi.org/10.1007/s00170-018-1981-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-1981-2