Effects of Cutting Parameters and Point Angle on Thrust Force and Delamination in Drilling of CFRP

2014 ◽  
Vol 56 (11-12) ◽  
pp. 1042-1048 ◽  
Author(s):  
Ahmet Yardimeden ◽  
Erol Kilickap ◽  
Yahya Hisman Celik
Keyword(s):  
Thrust Force ◽  
Cutting Parameters

scholarly journals Effect of Cutting Parameters and Tool Geometry on the Performance Analysis of One-Shot Drilling Process of AA2024-T3

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 854
Author(s):  
Muhammad Aamir ◽  
Khaled Giasin ◽  
Majid Tolouei-Rad ◽  
Israr Ud Din ◽  
Muhammad Imran Hanif ◽  
...  
Keyword(s):  
Feed Rate ◽  
Surface Defects ◽  
Thrust Force ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Machining Process ◽  
Tool Geometry ◽  
Drilling Process

Drilling is an important machining process in various manufacturing industries. High-quality holes are possible with the proper selection of tools and cutting parameters. This study investigates the effect of spindle speed, feed rate, and drill diameter on the generated thrust force, the formation of chips, post-machining tool condition, and hole quality. The hole surface defects and the top and bottom edge conditions were also investigated using scan electron microscopy. The drilling tests were carried out on AA2024-T3 alloy under a dry drilling environment using 6 and 10 mm uncoated carbide tools. Analysis of Variance was employed to further evaluate the influence of the input parameters on the analysed outputs. The results show that the thrust force was highly influenced by feed rate and drill size. The high spindle speed resulted in higher surface roughness, while the increase in the feed rate produced more burrs around the edges of the holes. Additionally, the burrs formed at the exit side of holes were larger than those formed at the entry side. The high drill size resulted in greater chip thickness and an increased built-up edge on the cutting tools.

scholarly journals A Force Sensorless Method for CFRP/Ti Stack Interface Detection during Robotic Orbital Drilling Operations

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
Author(s):  
Qiang Fang ◽  
Ze-Min Pan ◽  
Bing Han ◽  
Shao-Hua Fei ◽  
Guan-Hua Xu ◽  
...  
Keyword(s):  
Cutting Force ◽  
Thrust Force ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Reinforced Plastics ◽  
Orbital Drilling ◽  
Drilling Parameters ◽  
Drilling Operations ◽  
Machining Properties

Drilling carbon fiber reinforced plastics and titanium (CFRP/Ti) stacks is one of the most important activities in aircraft assembly. It is favorable to use different drilling parameters for each layer due to their dissimilar machining properties. However, large aircraft parts with changing profiles lead to variation of thickness along the profiles, which makes it challenging to adapt the cutting parameters for different materials being drilled. This paper proposes a force sensorless method based on cutting force observer for monitoring the thrust force and identifying the drilling material during the drilling process. The cutting force observer, which is the combination of an adaptive disturbance observer and friction force model, is used to estimate the thrust force. An in-process algorithm is developed to monitor the variation of the thrust force for detecting the stack interface between the CFRP and titanium materials. Robotic orbital drilling experiments have been conducted on CFRP/Ti stacks. The estimate error of the cutting force observer was less than 13%, and the stack interface was detected in 0.25 s (or 0.05 mm) before or after the tool transited it. The results show that the proposed method can successfully detect the CFRP/Ti stack interface for the cutting parameters adaptation.

scholarly journals Using artificial neural network models for the prediction of thrust force and torque in drilling operation of Al7075

2018 ◽  
Vol 178 ◽  
pp. 01008
Author(s):  
Panagiotis Kyratsis ◽  
Nikolaos Efkolidis ◽  
Daniel Ghiculescu ◽  
Konstantinos Kakoulis
Keyword(s):  
Thrust Force ◽  
Network Models ◽  
Cutting Parameters ◽  
Drilling Process ◽  
Neural Network Models ◽  
Cutting Velocity ◽  
Artificial Neural ◽  
Hidden Layer ◽  
The One ◽  
Tool Diameter

This study investigates the thrust force (Fz) and torque (Mz) in a drilling process of an Al7075 workpiece using solid carbide tools (Kennametal KC7325), depending on the effects of crucial cutting parameters such as cutting velocity, feed rate and tool diameter of 10mm, 12mm and 14mm. Artificial neural networks (ANN) methodology is used in order to acquire mathematical models for both the thrust force (Fz) and torque (Mz) related to the drilling process. The ANN results showed that the best prediction topology of the network for the thrust force was the one with five neurons in the hidden layer, while for the case of Mz the best network topology for the prediction of the experimental values was the one with six neurons in the hidden layer. Based on the results acquired, the ANN models achieved accuracy of 1,96% and 1,95% for both the thrust force and torque measured, while the R coefficient for the prediction model of the thrust force is 0.99976 and 00.99981 for the torque. As a result they can be considered as very accurate and appropriate for their prediction.

Drilling Force and Chip Morphology in Drilling of PCB Supported Hole

2011 ◽  
Vol 188 ◽  
pp. 429-434 ◽  
Author(s):  
L.P. Yang ◽  
Li Xin Huang ◽  
Cheng Yong Wang ◽  
L.J. Zheng ◽  
Ping Ma ◽  
...  
Keyword(s):  
Feed Rate ◽  
Printed Circuit Board ◽  
Thrust Force ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Spindle Speed ◽  
Circuit Board ◽  
Drilling Process ◽  
Drilling Force ◽  
Drill Bits

Supported holes of Printed circuit board (PCB) are drilled with two different drill bits. Drilling force (thrust force and torque) and chip morphology are examined at different cutting parameters, and the effects of the two drills are discussed. The results indicate that the drilling force and chip morphology are affected by the feed rate, spindle speed and drill shape. Thrust force increases with the increasing feed rate, and decreases with the increasing spindle speed. Optimization of drill geometry can reduce the thrust force significantly, and is effective in chip breaking which can improve the chip evacuation during the drilling process.

Experimental Study on Orbital Drilling Force and Machining Quality of CFRP

2014 ◽  
Vol 1061-1062 ◽  
pp. 542-549
Author(s):  
Xue Mei Chen ◽  
Qing Liang Chen ◽  
Feng Tao He ◽  
Xi Feng Fan
Keyword(s):  
Thrust Force ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Drilling Force ◽  
Drilling Tool ◽  
Orbital Drilling ◽  
Reinforced Plastic ◽  
Predominant Factor

This paper aims to investigate orbital drilling process in carbon-fiber reinforced plastic (CFRP) composites with multi-point orbital drilling tool based on the robot automatic drilling system. One orthogonal experiment has been carried out, and the cutting forces of different parameters were measured online by dynamometer. Furthermore, the cutting force model was established through regression analysis, and the impacts of cutting parameters on thrust force were deeply analyzed. In addition, delamination and tear defects were inspected respectively, and the relationship between thrust force and delamination and tear was discussed. Our results indicate that thrust force increased with the increasing feed rate and axial feed depth, while decreased with the increasing spindle speed. Axial feed depth was found as the predominant factor on thrust force and defects. At last, the cutting parameters was optimized and then thrust force decreased more than 26% with almost none tear and burr around the hole, which indicates a better machine quality.

Influence of cutting parameters during drilling of filled glass fabric-reinforced epoxy composites

2015 ◽  
Vol 22 (1) ◽  
pp. 81-88
Author(s):  
Murugesh Mudegowdar
Keyword(s):  
Surface Roughness ◽  
Thrust Force ◽  
Cutting Parameters ◽  
Glass Fabric ◽  
Tool Geometry ◽  
Matrix Composites ◽  
Machining Center ◽  
Delamination Factor ◽  
The Matrix ◽  
Drill Point

AbstractIn the present work, an attempt has been made to investigate the drilling behavior of the titanium dioxide (TiO2)- and zinc sulfide (ZnS)-filled glass fabric-reinforced polymer (GFRP) matrix composites. The volume fractions in the matrix were chosen as 1%, 2%, and 3%. Drilling has been conducted on CNC Vertical Machining Center. Speed and feed of drilling and drill tool geometry were considered as the varying parameters with three levels. Thrust force, delamination factor, and surface roughness have been considered as the output parameters and measured in each combination of parameters chosen. Results reveal that the addition of filler will increase the thrust force developed during drilling and indicate that drill point angle has a direct effect on the thrust value. Delamination factor increases with increase in feed and decreases as speed increases. Also, it can be observed that surface roughness decreases with increase in speed and increases with increase in feed. ZnS-filled composite shows less damage than TiO2.

scholarly journals Experimental Investigation On Machining Performance During Orbital Drilling of CFRP

2021 ◽  
Author(s):  
Linghao Kong ◽  
Dong Gao ◽  
Yong Lu ◽  
Pengfei Zhang
Keyword(s):  
Tool Wear ◽  
Thrust Force ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Machining Performance ◽  
Machining Quality ◽  
Orbital Drilling ◽  
Orthogonal Experiments ◽  
Hole Making ◽  
Tool Diameter

Abstract As the most promising CFRP hole making method, orbital drilling is widely concerned. This paper aims to understand the influence of the cutting parameters, tool diameters and ratio between milling and drilling (Rm&d) on thrust force, cutting temperature, tool wear and machining quality in CFRP orbital drilling. The effects of cutting parameters on thrust force and cutting temperature were studied by orthogonal experiments, and experiments were performed to investigate the variations of tool diameters, ratio between drilling and milling on thrust force, cutting temperature, tool wear and machining quality. The experimental results show that the tangential feed rate has no apparent effects on thrust force, but it appreciably impacts on the cutting temperature. The selection of tool diameter and the Rm&d has specific influence on tool wear, machining quality and cutting temperature. The result is helpful for selecting cutting parameters and tool diameters for high quality holes machining in CFRP orbital drilling.

Investigation on the Effect of Drilling Parameters on Quality of Hole in Epoxy Resin With and Without Carbon Fiber Reinforced With 6% and 10% Si3N4 Using FEA

2019 ◽  
Author(s):  
Holalu Venkatadasu Ravindra ◽  
Nodekoppalu Lingaiah Murali Krishna ◽  
Rakshith Gowda Doddagarudanahalli Shivaramaiah
Keyword(s):  
Surface Roughness ◽  
Carbon Fiber ◽  
Stress Distribution ◽  
Thrust Force ◽  
Equivalent Stress ◽  
Cutting Parameters ◽  
Maximum Principal Stress ◽  
Fiber Reinforced ◽  
Simulation Results

Abstract Now days drilling of fiber reinforced plastics become a challenging task in terms of obtaining defect free holes. Quality of drilling mainly depends on cutting parameters such as spindle speed, feed rate, diameter of the drill etc. Recently Finite element analysis (FEA) is found to be the most reliable method to investigate the effect of such parameters on quality of hole in drilling of composites. Present study focuses on the drilling of Epoxy resin with and without carbon fiber reinforced with 6% and 10% volume of Si3N4 composites as per the Taguchi’s L27 standard orthogonal array using HSS tool. FEA is carried out for each combination of cutting parameters given by taguchi’s table. Simulation results such as stress distribution, strain and deformation in the material are correlated with the with the drilled hole performance characteristics like Cylindricity, circularity, delamination and surface roughness. Simulation results depict the influence of thrust force and torque on the degree of deformation, strength, elasticity and stress distribution in the work material during drilling. From the simulation, it is found that deformation, and equivalent stress in the material decreases with increase in the % of Si3N4 reinforcement resulting in minimum surface roughness. The effect of feed rate is more on the value of thrust force resulting in maximum principal stress, equivalent stress and directional deformation in the material, which leads to delamination at the entry and exit of the hole. Further, influence of spindle speed is more on the value of torque resulting in maximum principal stress, equivalent stress and directional deformation in the material, which leads to maximum value of Cylindricity.

Effects of Cutting Parameters on Tool Wear and Thrust Force in Drilling Nickel-Titanium (NiTi) Alloys Using Coated and Uncoated Carbide Tools

2018 ◽  
Vol 791 ◽  
pp. 111-115 ◽  
Author(s):  
Rosmahidayu Rosnan ◽  
Azwan Iskandar Azmi ◽  
Muhamad Nasir Murad
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Thrust Force ◽  
Cutting Parameters ◽  
Nickel Titanium ◽  
Burr Formation ◽  
Machining Processes ◽  
Drilling Parameters ◽  
Mechanical Machining ◽  
Coated Carbide

The difficulties of machining nickel-titanium alloys are due to their high ductility and super-elasticity, strong strain-hardening, and excellent wear resistance. These characteristics lead to poor chip breakability, high cutting forces, rapid and aggressive tool-wear, as well as excessive burr formation during mechanical machining processes. The present study addresses these issues by evaluating the effects of drilling parameters and drill bit coatings on the growth of tool wear and development of the drilling thrust force. The findings from this research indicate that the TiAlN coated carbide drill was found to significantly improve the wear resistance of the cutting tool. Likewise, the results of thrust force development are consistent with the trends of tool wear growth for all of the tested carbide drills.

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