Delamination Analysis in Drilling Carbon Fiber-Reinforced Composites

2014 ◽  
Vol 697 ◽  
pp. 62-66
Author(s):  
Hong Fei Wang ◽  
Hua Zhou Li ◽  
Long Sheng Lu ◽  
Ying Xi Xie ◽  
Yu Xiao
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Thrust Force ◽  
Industrial Applications ◽  
Spindle Speed ◽  
Fiber Reinforced ◽  
Delamination Factor ◽  
Cfrp Composites ◽  
Drill Diameter ◽  
Carbon Fiber Reinforced

Due to its excellent performance, carbon fiber-reinforced plastics (CFRP) have been widely applied in industrial applications. The phenomenon of delamination can readily occur when drilling CFRP composites, which affects the quality of drilling holes. To effectively control the generation of processing defects, this paper focused on the analysis of the thrust force and the delamination factor. The delamination analysis was performed using graphs of the spindle speed, feed rate and drill diameter as independent parameters. The results suggest that there was a positive correlation between the delamination factor Fd and the thrust force Fz. The delamination factor decreases with increases in the spindle speed and increases with increases in the feed rate or with increases in the drill diameter. Based on the experimental data, this paper established a formula model of the delamination factor Fd, which would promote the further study of drilling CFRP composites.

Laminate Orientation Effect on Drilling of Carbon Fiber Reinforced Plastic Composites

2013 ◽  
Vol 315 ◽  
pp. 768-772
Author(s):  
Ismail Mahamad Hakimi ◽  
S. Sharif ◽  
Denni Kurniawan
Keyword(s):  
Carbon Fiber ◽  
Fiber Orientation ◽  
Thrust Force ◽  
Machining Process ◽  
Carbon Fiber Reinforced Plastic ◽  
Fiber Reinforced ◽  
Fiber Reinforced Plastic ◽  
Cfrp Composites ◽  
Reinforced Plastic ◽  
Carbon Fiber Reinforced

Carbon fiber reinforced plastic (CFRP) composites are often used in combination with other materials, requiring it to be machined during fabrication of a structure. Drilling as the most common machining process of CFRP is complex often results in delamination of the composites. The complexity is contributed by CFRP composites fiber orientation which can be of unidirectional or quasi-isotropic type depending on the applications. This study reviews the machinability of CFRP composites by considering fiber orientation and machining conditions used during drilling. Their relation with machining thrust force which leads to delamination is the central theme. An insight in obtaining delamination-free holes is also discussed.

Influence of Drill Geometry in Drilling Carbon Fiber Reinforced Plastics

2008 ◽  
Vol 375-376 ◽  
pp. 236-240 ◽  
Author(s):  
Chung Chen Tsao
Keyword(s):  
Carbon Fiber ◽  
Feed Rate ◽  
Thrust Force ◽  
Twist Drill ◽  
Fiber Reinforced ◽  
Pilot Hole ◽  
Cfrp Laminates ◽  
Reinforced Plastics ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced

Twist drill is widely used in hole-making process in industries, due their low production cost and ease of regrinding after wear. However, drilling of fiber reinforced plastics with twist drill often results in defects and damages, such as delamination, debonding, spalling and fiber pullout. The chisel edge of twist drill is the mainly influence for the thrust force and the hole quality in drilling carbon fiber reinforced plastic (CFRP) laminates. Pre-drilled pilot hole or reduce chisel edge can eliminate the threat for twist drill in drilling induced-delamination. Drilling-induced thrust force was selected as quality character factors to optimize the drilling parameters (drill type, feed rate and spindle speed) to get the smaller the better machining characteristics by Taguchi method. The results show that the feed rate and drill type are the most significant factor affecting the induced-thrust in drilling CFRP laminates.

scholarly journals Effect of Drilling Parameters Torque, Thrust Force and Delamination Factor on GFRP and CFRP Composites using Different Size of Drills

2020 ◽  
Vol 9 (1) ◽  
pp. 474-479
Keyword(s):  
Thrust Force ◽  
Industrial Applications ◽  
Fiber Reinforced Polymers ◽  
Drilling Process ◽  
Fiber Reinforced ◽  
Reinforced Polymers ◽  
Delamination Factor ◽  
Fiber Reinforced Polymer Composites ◽  
Drill Diameter ◽  
Helical Flute

The trend of the materials that are being used for various industrial applications has shown a drastic variation over the decades. Pure metals are replaced by alloys and these alloys in turn are being replaced by composites in most of the present day applications. Fiber reinforced polymer composites (FRPs) extensively used materials and a lot of research is going on for further improvement of properties of these materials. Drilling process is important in assembly of components in manufacturing. In case of FRPs drilling process is a great challenge when compared to that of conventional material because of de-bonding, metric cracking, and fiber pullout. The present work is a study on the effect of torque and thrust force on delamination of Carbon Fiber Reinforced Polymers (CFRP) and Glass Fiber Reinforced Polymers (GFRP) and by drilling process. Experiments are conducted at different feeds, drill diameters and speeds. Image processing approach is used to quantify the drill-induced delamination where helical flute HSS drills of diameters 4mm, 6mm and 8mm are used. Statistical analysis is made to optimize the drill parameters by ANOVA and Taguchi technique. It is observed that at 4mm drill diameter, torque and thrust force are minimum for both CFRP and GFRP. However, the delamination factor is minimum at drill diameter of 6mm in case of GFRP and at 8mm for CFRP

Optimization and sensitivity analysis of drilling parameters for sustainable machining of carbon fiber–reinforced polypropylene composites

2018 ◽  
Vol 32 (11) ◽  
pp. 1485-1508 ◽  
Author(s):  
M Mudhukrishnan ◽  
P Hariharan ◽  
K Palanikumar ◽  
B Latha
Keyword(s):  
Sensitivity Analysis ◽  
Carbon Fiber ◽  
Feed Rate ◽  
Thrust Force ◽  
Spindle Speed ◽  
Fiber Reinforced ◽  
Sustainable Machining ◽  
Modeling And Optimization ◽  
Drilling Parameters ◽  
Pp Composites

Machining processes face two major challenges: sustainability and cleaner production. However, the effective utilization of tool and methods of lubrication system in sustainable machining have been dealt in depth in earlier investigations. This work aims to optimize sustainable machining parameters in drilling process for recyclable carbon fiber-reinforced polypropylene (CFR-PP) composites. This work is focused on modeling and optimization of drilling parameters for sustainable machining with respect to thrust force and torque for CFR-PP composites. The response surface method based on D-optimal design of experiments is used for modeling and optimization with variables such as drill spindle speed and drill feed rate as numerical factors, which includes different drill material as the categorical factor. The influences of tool materials on the sustainable machining are also discussed in detail. Further, the sensitivity analysis is applied to compare the relative impact of control parameters (spindle speed, feed rate, and drill materials) on thrust force and torque. The scanning electron microscope images are used for analyzing the morphologies of drilled surfaces.

Experimental Investigation on the Tilt Helical Milling of Carbon Fiber Reinforced Plastics (CFRP)

2018 ◽  
Vol 792 ◽  
pp. 173-178
Author(s):  
Qiang Wang ◽  
Yong Bo Wu ◽  
Dong Lu ◽  
Teruo Bitoh ◽  
Ming Feng
Keyword(s):  
Carbon Fiber ◽  
Thrust Force ◽  
New Method ◽  
Helical Milling ◽  
Fiber Reinforced ◽  
Carbon Fiber Reinforced Plastics ◽  
Reinforced Plastics ◽  
Delamination Factor ◽  
Fiber Reinforced Plastics ◽  
Carbon Fiber Reinforced

Carbon fiber reinforced plastics (CFRP) has been widely used in various aircraft structural components. However, it is difficult for conventional methods such as drilling and helical milling to meet the requirements on high quality and efficient holes creation. Hence a so-called tilt helical milling (THM) method has been proposed. This new method is performed by replacing the revolving motion of the tool in conventional helical milling (CHM) with a conical pendulum motion, in which the tool axis is tilted towards the hole axis at a certain angle. As a step toward the establishment of the new method, in this work, the fundamental drilling characteristics of CFRP by the THM is elucidated by experimentally investigating the effects of tilt angle on thrust force and delamination factor. The obtained experimental results demonstrated that thrust force and delamination factor can be reduced with THM technique. In addition, THM can achieve better hole surface finish than CHM.

Experimental Study of Drilling Carbon Fiber-Reinforced Plastic (CFRP) with Candlestick Drill Using the Taguchi Method

2012 ◽  
Vol 472-475 ◽  
pp. 945-948
Author(s):  
Chung Chen Tsao
Keyword(s):  
Carbon Fiber ◽  
Taguchi Method ◽  
Feed Rate ◽  
Carbon Fiber Reinforced Plastic ◽  
Fiber Reinforced ◽  
Fiber Reinforced Plastic ◽  
Drilling Performance ◽  
Reinforced Plastic ◽  
Drill Diameter ◽  
Carbon Fiber Reinforced

In this paper, an approach is developed on Taguchi method to optimize the drilling parameters in drilling carbon fiber-reinforced plastic (CFRP) by the candlestick drill bits. The experimental results indicate that the feed rate (f) and the drill diameter (d) are the most important factors and the spindle speed (S) is insignificant in drilling CFRP laminates. The optimal drilling performance for the thrust force was obtained at 0.01 mm/rev feed rate, 800 rpm speed spindle and 6 mm drill diameter settings. The best combination to attain smaller delamination factor was 0.01 mm/rev feed rate, 800 rpm speed spindle and 10 mm drill diameter.

Effects of Twist Drill Point Angle on Thrust Force and Delamination Factor in Hybrid Fiber Composites Drilling

2014 ◽  
Vol 564 ◽  
pp. 501-506 ◽  
Author(s):  
Mohd Azuwan Maoinser ◽  
Faiz Ahmad ◽  
Safian Shariff ◽  
Tze Keong Woo
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Polymeric Composite ◽  
Drilling Process ◽  
Twist Drill ◽  
Fiber Reinforced ◽  
Hybrid Fiber ◽  
Frp Composites ◽  
Delamination Factor ◽  
Drill Point

Drill point angle of twist drill has a significant effect on thrust force and delamination factor on drilled holes in fiber reinforced polymer (FRP) composites. In this study, three drill point angle of twist drill; 85°, 118° and 135° were used to drill holes in hybrid fiber reinforced polymeric composite (HFRP). HFRP composites were fabricated using vacuum infusion molding (VIM) technique. The test samples were cured at 90°C for two hours. In drilling process various drill point angle and feed rate were employed to investigate the effect of both parameters on thrust force and delamination factor when drilling the HFRP composite. The results showed that small drill point angle and low feed rate can reduce the thrust force leading to the reduction of damage factor at the holes entrance and exit.

scholarly journals A prediction model of thrust force for drilling of bidirectional carbon fiber–reinforced carbon matrix composites

2020 ◽  
Vol 103 (2) ◽  
pp. 003685042092522
Author(s):  
Chenwei Shan ◽  
Shengnan Zhang ◽  
Menghua Zhang ◽  
Kaifeng Qin
Keyword(s):  
Carbon Fiber ◽  
Prediction Model ◽  
Thrust Force ◽  
Carbon Matrix ◽  
Fiber Reinforced Polymer ◽  
Material Structure ◽  
Matrix Composites ◽  
Fiber Reinforced ◽  
Reinforced Polymer ◽  
Carbon Fiber Reinforced

Carbon fiber–reinforced carbon matrix composites have been widely used for the manufacturing of thermostructural parts for several industries such as the aerospace and automotive. Drilling is an extremely common method used in the machining of carbon fiber–reinforced carbon matrix composites before assembly. However, their non-homogeneous, anisotropic, and brittle nature make difficult to guarantee the hole quality in drilling. Some severe drilling defects, such as burrs, delamination, and tear, usually occur. In this regard, it is necessary to accurately predict the thrust force in drilling of carbon fiber–reinforced carbon matrix composites. Therefore, in this article, based on the cutting theory of fiber-reinforced polymer composites, an alternative thrust force prediction model for drilling of bidirectional carbon fiber–reinforced carbon matrix composites is proposed. The cutting force of the cutting lips is established by dividing the cutting deformation zone into three regions according to the machined material structure based on the Zhang’s model in cutting of fiber-reinforced polymer. The periodic variation of fiber orientation is considered in detail. The experimental results show that the relative deviations of the predicted and experimental values of the thrust force are less than 14.36%.

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