Forming and drilling of fiber metal laminates – A review

2018 ◽  
Vol 37 (14) ◽  
pp. 981-990 ◽  
Author(s):  
M Thirukumaran ◽  
I Siva ◽  
JT Winowlin Jappes ◽  
V Manikandan
Keyword(s):  
Process Parameters ◽  
Failure Modes ◽  
Machining Parameters ◽  
Fiber Metal Laminates ◽  
Aerospace Applications ◽  
Fiber Metal ◽  
Process Combination ◽  
Joining Process ◽  
Quality Production

In aviation industries, most of the stiffened structural components are manufactured by forming and laminating process. Combination of several conventional manufacturing processes is required in modern industries in hybrid laminate production. Fiber metal laminates undergo various joining process during assembly of aero-structures. Among them, forming and drilling are often required during assembly. Understanding the significance of various process parameters enables quality production and assembly of fiber metal laminates structures. Many researchers explored the cause and effect of few parameters and mechanisms which significantly alter the quality of form and drill. This review describes the progress in forming and drilling of fiber metal laminates for aerospace applications. Especially towards the process parameters, defects and their causes along with the preferred solutions recommended by the researcher society in forming and drilling processes. Numerous factors have controlled the quality of forming and drilling processes. Due to the machining parameters, different failure modes will occur in different layup of the laminates. To overcome the failures in machining/forming of fiber metal laminates, choosing the optimum parameter for the selection based procedure is needed to improve quality of fiber metal laminates.

A review of mechanical drilling on fiber metal laminates

2020 ◽  
pp. 002199832095774
Author(s):  
Eduardo Pires Bonhin ◽  
Sarah David-Müzel ◽  
Manoel Cléber de Sampaio Alves ◽  
Edson Cocchieri Botelho ◽  
Marcos Valério Ribeiro
Keyword(s):  
Mechanical Properties ◽  
Cutting Parameters ◽  
Burr Formation ◽  
Drilling Process ◽  
Machining Parameters ◽  
Specific Mass ◽  
Fiber Metal Laminates ◽  
Dimensional Error ◽  
Main Method ◽  
Fiber Metal

The use of fiber metal laminates (FML) in aeronautics components has been increased in the last years, mainly due to the gain in mechanical properties combined with low specific mass. However, in the assembly of these materials on the structures to which they will be attached, mechanical screwing is still the main method used, which requires the performance of drilling processes. Something it is very complicated for these materials and can cause damage that compromises the performance. Therefore, this work aims to approach and summarize the evolution of the mechanical drilling process on FML developed in the last years. By the work, the main problems that occur during the drilling of these materials are punctually approached, such as delamination, burr formation, dimensional error, poor roughness, and tool wear. In addition, it is presented how these problems are affected by the machining parameters (cutting parameters, geometry, material/coating tool, and cutting environment), as well as suggestions for minimizing process problems. Thus, the article intends to provide as much information as possible available in the literature, seeking to help researchers gain a comprehensive view of the mechanical drilling of fiber metal laminates.

scholarly journals Automated, Quality Assured and High Volume Oriented Production of Fiber Metal Laminates (FML) for the Next Generation of Passenger Aircraft Fuselage Shells

2019 ◽  
Vol 26 (1) ◽  
pp. 502-508 ◽  
Author(s):  
Hakan Ucan ◽  
Joachim Scheller ◽  
Chinh Nguyen ◽  
Dorothea Nieberl ◽  
Thomas Beumler ◽  
...  
Keyword(s):  
Research Work ◽  
Research Programme ◽  
High Volume ◽  
Next Generation ◽  
New Production ◽  
Fiber Metal Laminates ◽  
Production Chain ◽  
Joint Project ◽  
Aerospace Applications ◽  
Fiber Metal

AbstractThe use of fiber-metal laminates (FML) allows for substantial advantages over a fuselage skin made of monolithic aluminum materials. Glass fiber prepreg reinforced aluminium is characterized by high damage tolerance capabilities, supporting the structural strength capability in case of any kind of damage. For this reason, FML, and GLARE in particular, have been identified as superior materials for aerospace applications. More than 400m2 FML is applied on each A380, as skin panels and as D-noses for both, vertical and horizontal stabilizer. FML possess the potential to become the baseline material for next-generation single-aisle aircrafts [1, 2, 6].The development of a new production chain that will allow automated fuselage production for future short-haul aircrafts is the focus of the studies that make up the joint project AUTOGLARE. As part of the fifth call-up for the German Aeronautical Research Programme (LuFo), the German Aerospace Center (DLR) is working with its project partners Airbus Operations, Premium Aerotech (PAG) and the Fraunhofer Gesellschaft (FhG). The development of a production chain for stiffened fuselage panels made of Fiber metal Laminates should support a production rate of 60 aircraft per month [3].This study contains the research work of the DLR and FhG regarding the automated and quality assured process for chain stiffened FML fuselages. In addition to a detailed explanation of the systems that were set up, this paper covers the planned tests, the completed demonstration models and the findings derived from them.

scholarly journals Analysis of WEDM Process Parameters on Surface Roughness and Kerf using Taguchi Method

2017 ◽  
Vol 2 (4) ◽  
pp. 103-109 ◽  
Author(s):  
Asfana Banu ◽  
Mazilah Abu Bakar ◽  
Mohammad Yeakub Ali ◽  
Erry Y. T. Adesta
Keyword(s):  
Surface Roughness ◽  
Taguchi Method ◽  
Process Parameters ◽  
Dielectric Fluid ◽  
Tool Electrode ◽  
Machining Parameters ◽  
Wire Tension ◽  
Wedm Process ◽  
Off Time

In obtaining the best quality of engineering parts, the quality of machined surface plays an essential role. The fatigue strength, wear resistance, and corrosion of workpiece are some of the aspects of the qualities that can be improved. This paper investigates the effect of wire electrical discharge machining (WEDM) process parameters on surface roughness and kerf on stainless steel using distilled water as dielectric fluid and brass wire as tool electrode. The selected process parameters are voltage open, wire speed, wire tension, voltage gap, and off time. Empirical models using Taguchi method were developed for the estimation of surface roughness and kerf. The analysis revealed that off time has major influence on surface roughness and kerf. The optimum machining parameters for minimum surface roughness and kerf were found to be 10 V open voltage, 2.84 µs off time, 12 m/min wire speed, 6.3 N wire tension, and 54.91 V voltage gap. 

Ballistic performance and damage simulation of fiber metal laminates under high-velocity oblique impact

2020 ◽  
Vol 29 (7) ◽  
pp. 1011-1034 ◽  
Author(s):  
Chao Zhang ◽  
Qian Zhu ◽  
Jose L Curiel-Sosa ◽  
Tinh Quoc Bui
Keyword(s):  
Impact Velocity ◽  
High Velocity ◽  
Damage Mechanics ◽  
Failure Modes ◽  
Element Model ◽  
Oblique Impact ◽  
Ballistic Performance ◽  
Fiber Metal Laminates ◽  
Fiber Metal ◽  
The Impact

Fiber metal laminates have been successfully applied in military aircrafts, armor vehicles and other modern engineering industries as protective structures due to their outstanding impact resistant properties. Prediction of the ballistic performance and investigation on the damage mechanism of the fiber metal laminates under general oblique impact conditions still remain a very challenging issue. In this study, a nonlinear dynamic finite element model in terms of continuum damage mechanics including intra- and inter-layer failure modes is presented. The accuracy of this model is validated with available experimental data. The damage and ballistic performance of two different structural fiber metal laminates subjected to high-velocity oblique impact by rigid hemispherical nose projectile with angles of 0°, 30°, 45° and 60° are studied. The numerical results show that the projectile deflects when the oblique impact occurs and the deflection angle decreases with increasing the impact velocity. The residual velocity of the projectile and the energy absorption of the target are related to the initial impact velocity and impact angle of the projectile. The proposed simulation approach offers a new proper reference for numerical investigations of common oblique impact problems in other fiber metal laminates.

scholarly journals Examination on Mechanical Behavior and Drilling Analysis of Fiber Metal Laminates

2019 ◽  
Vol 9 (1S4) ◽  
pp. 881-885
Keyword(s):  
Mechanical Behavior ◽  
Optical Microscope ◽  
Drill Bit ◽  
Compression Moulding ◽  
Fiber Metal Laminates ◽  
Aerospace Applications ◽  
Before And After ◽  
New Type ◽  
Fiber Metal ◽  
Aluminium Sheets

Fiber Metal Laminates (FML) are a class of composites that are recently employed to substitute sole metals in various applications like aerospace applications. In this investigation, a new type of FML was successfully fabricated using compression moulding in which Aluminium and ceramics mat are stacked in the presence of epoxy resin. To improve the bonding by ensuring the flow of resin through the laminates, drilling with various pattern on the Aluminium sheet and ceramic mat were performed before subjected to compression to form FML. Aluminium sheets with Zig-zag pattern performed in a better way due to the improvements in bonding. In addition, drilling operation was done on the FML to ensure the de-lamination resistance and machinability. The drill bit before and after drilling was inspected by using optical microscope to understand the machinability behaviour of the FML.

scholarly journals Analysis of the bending and failure of fiber metal laminates based on glass and carbon fibers

2018 ◽  
Vol 25 (6) ◽  
pp. 1095-1106 ◽  
Author(s):  
Monika Ostapiuk ◽  
Jarosław Bieniaś ◽  
Barbara Surowska
Keyword(s):  
Carbon Fibers ◽  
Failure Modes ◽  
Fiber Type ◽  
Composite Layer ◽  
Matrix Cracking ◽  
Aluminum Layer ◽  
Fiber Metal Laminates ◽  
Aluminum Sheets ◽  
Fiber Metal ◽  
Metal Layers

AbstractThe purpose of this paper is to investigate the mechanisms of cracking and failure in fiber metal laminates (FMLs) subjected to 3-point bending. Two types of laminates, based on the glass/epoxy and carbon/epoxy composites, were selected for the study. The paper presents the failures of matrix and fibers as well as the effects of different thicknesses of metal layers on the tested laminates. The mechanisms of failure observed for the two tested types of fibers with uniform thickness of aluminum sheets seem similar. The results demonstrate that the tested laminates exhibit the following failure modes: fiber breakage, matrix cracking, fiber/matrix debonding, delamination, and anodic layer failure. Given the behavior of aluminum under the compressive and tensile stresses, the aluminum layer acts as a barrier preventing FML failure during bending. In addition to aluminum layer thickness, the fiber type and composite layer directions are also important factors to be considered.

Influence of process parameters on bond properties of Al laminated structure produced by ultrasonic consolidation

2016 ◽  
Vol 22 (2) ◽  
pp. 435-442 ◽  
Author(s):  
Xiao-Hua He ◽  
Hui-Ji Shi ◽  
Mark Norfolk
Keyword(s):  
Aluminum Alloys ◽  
Bond Strength ◽  
Process Parameters ◽  
Failure Modes ◽  
Bond Quality ◽  
Laminated Structure ◽  
Ultrasonic Consolidation ◽  
Content Type ◽  
Laminated Structures

Purpose The purpose of this paper is to investigate the influence of key parameters on the bond strength and failure modes of laminated structures made of different aluminum alloys (i.e. Al 2024 and Al 7075) via the ultrasonic consolidation (UC) process. Design/methodology/approach The UC is used to fabricate laminated structures with various parameters. The push-pin tests were performed on the specimens of different materials and parameters, and the force and displacement were recorded during the tests. The peak punch force was used to represent the bond quality of the laminated structure, and the curves of force versus displacement were used to study the failure modes of the structures. Findings It is found that the lower normal force, the larger vibration amplitude and the lower travel speed can result in stronger bonding. Three different failure modes are observed in the tests, due to the different relations between the toughness of interface and raw materials. The process parameters have influence on the interface toughness of a laminated structure, which further leads to different failure modes. Originality/value The overall mechanical properties of a laminated structure highly depend on the bond quality between laminated layers. The push-pin test can easily and effectively evaluate the bond quality of the laminated structure. This paper not only focuses on the bond strength evaluation, but also analyzes the different failure modes of laminated structures made of different aluminum alloys, which can give an opportunity to optimize the parameters for different materials.

scholarly journals Bearing Strength and Failure Modes Analysis of Carbon Reinforced Aluminium Laminate

2019 ◽  
Vol 8 (10) ◽  
pp. 2573-2578
Keyword(s):  
Failure Modes ◽  
Diameter Ratio ◽  
Hole Diameter ◽  
Bearing Failure ◽  
Fiber Metal Laminates ◽  
Bearing Strength ◽  
Fiber Metal

Objective of this paper is study the bearing strength and failure modes of the Fiber Metal Laminates prepared by hand layup technique in two different stacking sequences. Parameters like ratio of hole distance to hole diameter (e/D), ratio to the width of composite to hole diameter (W/D) are varied during the experiment. Hole diameter is kept constant as 6mm and e value is taken as 6mm, 12mm, 18mm, 24mm, 30mm and 36mm. Similarly the width of the FML specimen is maintained as 24mm and 36mm respectively. Results show that laminate with [Ca0°/Ca90°/Al/Ca90°/Ca0°]s orientation is having a bearing strength 3.94% higher than that of [Al/Ca0°/Ca90°/Al/Ca0°]s orientation. In terms of failure modes the specimens with distance-diameter ratio greater than 3 and the two width- diameter ratio 4 and 6 exhibited bearing failure. For smaller ratios, the failure is due to shear out which involves combination of bearing and net tension failure.

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