Drilling of Carbon Fibre Composites: A Review

2014 ◽  
Vol 903 ◽  
pp. 3-8 ◽  
Author(s):  
Aishah Najiah Dahnel ◽  
Stuart Barnes ◽  
Pipat Bhudwannachai
Keyword(s):  
Tool Wear ◽  
Carbon Fibre ◽  
Feed Rate ◽  
Cutting Tool ◽  
Thrust Force ◽  
Fibre Composite ◽  
Cutting Speed ◽  
Heterogeneous Structure ◽  
Drilling Performance ◽  
Carbon Fibre Composites

Machining of Carbon Fibre Composite (CFC), particularly drilling is frequently employed in many industries especially when dealing with joining, assembly and structural repair of the parts. This paper summarizes the properties of the CFC as well as the appropriate material and geometry of the cutting tool that should be used when drilling of the CFC in order to optimize the drilling performance. In addition, this work also presents the literature review on the relationship between cutting speed, feed rate, tool wear, thrust force and damage of the drilled CFC. The nature and heterogeneous structure of CFC often resulted in difficulty during their machining in terms of rapid tool wear and high thrust force. As a result, this always results in the damage of the drilled parts. Furthermore, higher cutting speed and lower feed rate are also recognized as significant factors which contribute to rapid wear of the cutting tool. Therefore, the use of tungsten carbide cutting tools, cutting fluids and cryogenic machining is seen to be a practical technique in optimizing the drilling performance involving CFC. In general, this work intends to provide a basic guideline and understanding regarding drilling of the CFC.

Experimental Analysis of Tool Wear when Drilling Carbon Fibre Composite (CFC) without Cutting Fluid, with Cutting Fluid and with a Pre-Cryogenically Cooled Tool

2013 ◽  
Vol 372 ◽  
pp. 512-515
Author(s):  
Aishah Najiah Dahnel ◽  
Stuart Barnes ◽  
Pipat Bhudwannachai
Keyword(s):  
Tool Wear ◽  
Carbon Fibre ◽  
Fibre Composite ◽  
Cutting Speed ◽  
Cryogenic Cooling ◽  
Cutting Fluid ◽  
Heterogeneous Structure ◽  
Carbon Fibre Composite ◽  
Dry Drilling ◽  
Carbon Fibre Composites

Machining of Carbon Fibre Composites (CFCs) particularly drilling, is frequently employed in industry especially when dealing with joining, assembly and structural repair of the parts. However, the nature and heterogeneous structure of CFCs often results in rapid wear of the cutting tool. This research studied the relationship and compared the effect of drilling a CFC plaque without cutting fluid, with conventional cutting fluid and with cryogenic cooling at constant cutting speed of 94 m/min and feed rate of 0.065 mm/revolution using tungsten carbide twist drill. The conventional cutting fluid was supplied continuously to the drill and the CFC plaque during the drilling cycle; while for the cryogenic cooling tests, the drill tip was immersed in liquid nitrogen for 10 and 30 seconds prior to drilling the CFC. It was found that the tool wear increased with the increasing number of drilled holes at all machining conditions. After drilling of 325 holes, the largest tool wear observed was 181 μm which was produced when drilling the CFC plaque with conventional cutting fluid. The corresponding tool wear for drilling with cryogenic cooling was 164 μm and the smallest tool wear of 155 μm was observed during dry drilling. Dry drilling produced the smallest tool wear because the heat generated reduced the strength of the CFC, particularly polymer matrix. Therefore, this situation led to easier machining of CFC materials; consequently reduced the wear of the tool.

scholarly journals System for Tool-Wear Condition Monitoring in CNC Machines under Variations of Cutting Parameter Based on Fusion Stray Flux-Current Processing

Sensors ◽  
2021 ◽  
Vol 21 (24) ◽  
pp. 8431
Author(s):  
Arturo Yosimar Jaen-Cuellar ◽  
Roque Alfredo Osornio-Ríos ◽  
Miguel Trejo-Hernández ◽  
Israel Zamudio-Ramírez ◽  
Geovanni Díaz-Saldaña ◽  
...  
Keyword(s):  
Tool Wear ◽  
Condition Monitoring ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Economic Benefits ◽  
Numerical Control ◽  
Cnc Machines ◽  
Cutting Tool Wear

The computer numerical control (CNC) machine has recently taken a fundamental role in the manufacturing industry, which is essential for the economic development of many countries. Current high quality production standards, along with the requirement for maximum economic benefits, demand the use of tool condition monitoring (TCM) systems able to monitor and diagnose cutting tool wear. Current TCM methodologies mainly rely on vibration signals, cutting force signals, and acoustic emission (AE) signals, which have the common drawback of requiring the installation of sensors near the working area, a factor that limits their application in practical terms. Moreover, as machining processes require the optimal tuning of cutting parameters, novel methodologies must be able to perform the diagnosis under a variety of cutting parameters. This paper proposes a novel non-invasive method capable of automatically diagnosing cutting tool wear in CNC machines under the variation of cutting speed and feed rate cutting parameters. The proposal relies on the sensor information fusion of spindle-motor stray flux and current signals by means of statistical and non-statistical time-domain parameters, which are then reduced by means of a linear discriminant analysis (LDA); a feed-forward neural network is then used to automatically classify the level of wear on the cutting tool. The proposal is validated with a Fanuc Oi mate Computer Numeric Control (CNC) turning machine for three different cutting tool wear levels and different cutting speed and feed rate values.

scholarly journals Experimental Investigation of Thrust Force, Delamination and Surface Roughness in Drilling Hybrid Structural Composites

Materials ◽  
2021 ◽  
Vol 14 (16) ◽  
pp. 4468
Author(s):  
Vigneshwaran Shanmugam ◽  
Uthayakumar Marimuthu ◽  
Sundarakannan Rajendran ◽  
Arumugaprabu Veerasimman ◽  
Adamkhan Mahaboob Basha ◽  
...  
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Hybrid Composites ◽  
Cutting Speed ◽  
Burr Formation ◽  
Sisal Fibre ◽  
Drilling Performance ◽  
Fibre Composites ◽  
Structural Applications ◽  
Polyester Matrix

Filled hybrid composites are widely used in various structural applications where machining is critical. Hence, it is essential to understand the performance of the fibre composites’ machining behaviour. As such, a new hybrid structural composite was fabricated with redmud as filler and sisal fibre as reinforcement in polyester matrix. The composite was then tested for its drilling performance. A comprehensive drilling experiment was conducted using Taguchi L27 orthogonal array. The effect of the drill tool point angle, the cutting speed, the feed rate on thrust force, delamination, and burr formation were analysed for producing quality holes. The significance of each parameter was analysed, and the experimental outcomes revealed some important findings in the context of the drilling behaviour of sisal fibre/polyester composites with redmud as a filler. Spindle speed contributed 39% in affecting the thrust force, while the feed rate had the maximum influence of ca. 38% in affecting delamination.

scholarly journals Experimental Study on Drilling MDF with Tools Coated with TiAlN and ZrN

Materials ◽  
2019 ◽  
Vol 12 (3) ◽  
pp. 386 ◽  
Author(s):  
Krzysztof Szwajka ◽  
Joanna Zielińska-Szwajka ◽  
Tomasz Trzepiecinski
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Thrust Force ◽  
Medium Density Fiberboard ◽  
Cutting Speed ◽  
Piezoelectric Sensor ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Aesthetic Appearance

There is increasing use of wood-based composites in industry not only because of the shortage of solid wood, but above all for their better properties such as: strength, aesthetic appearance, etc., compared to wood. Medium density fiberboard (MDF) is a wood-based composite that is widely used in the furniture industry. The goal of the research conducted was to determine the effect of the type of coating on the drill cutting blades on the value of thrust force (Ft), cutting torque (Mc), cutting tool temperature (T) and surface roughness of the hole in drilling MDF panels. In the tests, three types of carbide drills (HW) were used: not coated, TiAlN coated and ZrN coated. The measurement of both the thrust force and the cutting torque was carried out using an industrial piezoelectric sensor. The temperature of the cutting tool in the drilling process was measured using an industrial temperature measurement system using a K-type thermocouple. It was found that the value of the maximum temperature of the tool in the drilling process depends not only on the cutting speed and feed rate, but also on the type of coating of the cutting tool. The value of both the cutting torque and the thrust force is significantly influenced by the value of the feed rate and the type of drill coating. The effect of varying plate density on the surface roughness of the hole and the variation of the value of the thrust force is also discussed. The results of the investigations were statistically analyzed using a multi-factorial analysis of variance (ANOVA).

scholarly journals Experimental Study on Drilling MDF with Tools Coated with TiAlN and ZrN

2019 ◽  
Author(s):  
Krzysztof Szwajka ◽  
Joanna Zielńska-Szwajka ◽  
Tomasz Trzepieciński
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Cutting Tool ◽  
Thrust Force ◽  
Cutting Speed ◽  
Piezoelectric Sensor ◽  
Solid Wood ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Aesthetic Appearance

There is increasing use of wood-based composites in industry not only because of the shortage of solid wood, but above all for their better properties such as: strength, aesthetic appearance, etc. compared to wood. Medium density fibreboard (MDF) is a wood-based composite that is widely used in the furniture industry. The goal of the research conducted was to determine the effect of the type of coating on the drill cutting blades on the value of thrust force (Ft), cutting torque (Mc), cutting tool temperature (T) and surface roughness of the hole in drilling MDF panels. In the tests three types of carbide drills (HW) were used: not coated, TiAlN coated and ZrN coated. The measurement of both the thrust force and the cutting torque was carried out using an industrial piezoelectric sensor. The temperature of the cutting tool in the drilling process was measured using an industrial temperature measurement system using a K-type thermocouple. It was found that the value of the maximum temperature of the tool in the drilling process depends not only on the cutting speed and feed rate, but also on the type of coating of the cutting tool. The value of both the cutting torque and the thrust force is significantly influenced by the value of the feed rate and the type of drill coating. The effect of varying plate density on the surface roughness of the hole and the variation of the value of the thrust force is also discussed. The results of the investigations were statistically analysed using a multi-factorial analysis of variance (ANOVA).

The Effect of Milling Parameters on Laminated Carbon Fibre Reinforced Plastic (CFRP)

2012 ◽  
Vol 59 (2) ◽  
Author(s):  
M. K. N. Khairusshima ◽  
C. H. Che Hassan ◽  
A. G. Jaharah ◽  
A. K. M. Amin
Keyword(s):  
Carbon Fibre ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Dimensional Precision ◽  
Reinforced Plastic ◽  
Cfrp Composite ◽  
Feasible Alternative ◽  
Materials Used ◽  
Carbon Fibre Reinforced Plastic

The demand is high in various applications for an inexpensive and feasible alternative to engineering material, namely, the carbon fibre reinforced plastic (CFRP) composite. CFRP is one of the main materials used as a substitute for glass and aramid in aerospace industries. However, many problems arise during machining. Abrasive wear, poor surface finish, burr, and de-lamination, among others, are the common difficulties encountered by the machinist. These problems occur because of the existence of carbon in the CFRP that affects the performance of the tool and the surface quality of the end product. A solid uncoated carbide end mill cutting tool and a CFRP panel with fibre orientation of 0/45° were used to investigate the machinability of CFRP composite during milling; a cutting speed of 16 m/min to 240 m/min with a feed rate of 0.0125 mm/tooth to 0.0125 mm/tooth were set. At higher cutting speed and feed rate, the performance of carbide cutting tool worsens, similar to the de-lamination factor. Tool life is longer at lower cutting speed and feed rate, but a better quality surface is achieved at higher cutting speed. The dimensional precision of CFRP is also better at higher cutting speed and lower feed rate.

Tool Wear in Machining AlSi/AlN Metal Matrix Composite 10 Wt% Reinforcement Using Uncoated Cutting Tool

2013 ◽  
Vol 465-466 ◽  
pp. 973-977
Author(s):  
M.S. Said ◽  
M.S. Yusoff ◽  
C.H. Che Hassan ◽  
Mohd Asri Selamat ◽  
J.A. Shukur ◽  
...  
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Low Density ◽  
Industrial Sectors

Aluminum silicon (Al/Si) alloy, a metal matrix composite (MMC), is widely used in various industrial sectors, such as transportation, domestic equipment, aerospace, military, and construction. Al/Si alloy is a matrix composite reinforced with aluminum nitride (AlN) particle and transformed into a new-generation material for automotive and aerospace applications. AlN material is an advanced material characterized by light weight, high strength, and high hardness and stiffness, which makes it suitable for various future applications. However, its high ceramic particle reinforcement and the irregular nature of these particles along the matrix material make it a low density material. This low density is the main cause of problems during machining of this material. This paper studies tool wear in milling AlSi/AlN metal matrix composite by using an uncoated carbide cutting tool. The volume of AlN reinforced particle was 10%. The milling process was carried out under dry cutting conditions. The uncoated carbide insert parameters used were the following: cutting speed of 230 m/min to 370 m/min, feed rate of 0.4, 0.6, and 0.8 mm/tooth, and a corresponding depth of cut (DOC) of 0.3, 0.4, and 0.5 mm, respectively. Sometech SV-35 video microscope system was used for tool wear measurements. Results revealed that tool wear increases at 230 m/min cutting speed, 0.4 mm/tooth feed rate, and 0.3 mm depth of cut. The medium cutting speed, specifically the 300 m/min cutting speed, 0.4 mm/tooth feed rate, and 0.5 mm DOC, is the optimum condition for a longer tool life (82.94 min) and is ideal for cutting AlSi/AlN MMCs.

scholarly journals Comparative Analysis in Drilling Performance of AA7075 in Different Temper Conditions

2021 ◽  
Author(s):  
ESER YARAR ◽  
Alpay Tamer ERTURK ◽  
Funda Gül KOÇ ◽  
Fahri VATANSEVER
Keyword(s):  
Tool Wear ◽  
Surface Quality ◽  
Heat Generation ◽  
Chip Formation ◽  
Feed Rate ◽  
Thrust Force ◽  
Spindle Speed ◽  
Drill Bit ◽  
Microstructural Properties ◽  
Drilling Performance

Abstract AA7075 is one of the most suitable materials for aerospace, aircraft, and defense applications with its high yield strength and low-density. In many other modern machining methods, conventional drilling remains the most extensive material removal process in industrial components. The main objective of this study is examining the machinability and surface quality conditions of the AA7075 material with different temper conditions. For this purpose, various temper treatments are implemented to evaluate the impact of microstructural properties on tool wear and surface quality of the drilled holes. The drilling operations have been done on O, F, T4, T6, and T7 temper conditions. Process parameters were three different spindle speeds (715, 1520, and 3030 rev/min) and three feed rates (0.1, 0.2, and 0.3 mm/rev) with HSS-G high-performance ground standard twist drill bit. The present work deals with the effects of temper conditions on thrust force, drilling temperature, tool wear, surface integrity, and chip morphology. Drilling performance is related to the intrinsic microstructural properties of temper conditions. Response surface methodology was used in the evaluation of experiment results. The optimization results showed that while thrust force and torque are not significantly affected by change in spindle speed, they are sensitive to increase in feed rate. Heat-generation on the drill bit is the lowest at low levels of both the feed rate and spindle speed parameters. Among different temper conditions, the AA7075-T6 condition sample is processed with continuous chip formation and resulted in the best hole surface quality. The 3D finite element modelling of the drilling process was carried out, and the drilling performance of AA7075-T6 was evaluated in terms of thrust force, heat generation, and chip formation.

Investigation on Drilling Performance of Titanium Alloy Ti6Al4V Based on Response Surface Method

2017 ◽  
Author(s):  
Zhaoju Zhu ◽  
Shaochun Sui ◽  
Jie Sun ◽  
Jianfeng Li ◽  
Kai Liu
Keyword(s):  
Surface Roughness ◽  
Response Surface ◽  
Response Surface Method ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Drilling Performance ◽  
Surface Method ◽  
Low Efficiency

In order to break the bottleneck of low efficiency, bad quality following drilling alloy Ti6Al4V, the effect of cutting parameters on thrust force, drilling vibration, burr height and surface roughness was studied based on response surface method. The optimized parameters were obtained. Results showed that feed rate had significant effect on thrust force and little on drilling vibration, while cutting speed had significant effect on vibration and little on thrust force. It is also observed that surface roughness decreased with cutting speed increasing, as well as increased with feed rate increasing. In addition, microstructure on the drilled hole surface showed mobility along feeding direction. Grain refinement on the drilling hole surface became serious with the increase of cutting speed and feed rate.

Modelling of thrust force for worn drill bits characterised by cutting edge radius in drilling carbon fibre–reinforced plastic/Ti-6Al-4V alloy stacks

2017 ◽  
Vol 232 (11) ◽  
pp. 1960-1972 ◽  
Author(s):  
Bin Luo ◽  
Kaifu Zhang ◽  
Yuan Li ◽  
Hui Cheng ◽  
Shunuan Liu
Keyword(s):  
Tool Wear ◽  
Carbon Fibre ◽  
Feed Rate ◽  
Thrust Force ◽  
Cutting Edge Radius ◽  
Reinforced Plastics ◽  
Edge Radius ◽  
Drill Bits ◽  
Carbon Fibre Reinforced Plastics ◽  
Maximum Thrust

Wear rates are rapid when drilling carbon fibre–reinforced plastics/Ti-6Al-4V alloy stacks because of their distinct mechanical properties. Tool wear leads to a high thrust force, thereby reducing the quality of the drilled holes. This article develops a novel mechanistic model for carbon fibre–reinforced plastics/Ti-6Al-4V stacks, which is characterised by the cutting edge radius, to predict the variation of the thrust force when drilling with worn drill bits. Drilling experiments with varying feed rates were performed using carbide twist drill bits. The thrust force and drill edge profile were measured to calibrate and validate the presented model. The edge radius increases with both the cutting distance and number of drilled holes at varying feed rates. It was found that the growth rate of the edge radius increased with the feed rate with identical cutting distances, whereas it decreased slightly with the feed rate when the number of drilled holes was identical. Tool wear reduces the equivalent rake angle of the drill edge, resulting in higher thrust force. The maximum thrust force increases almost linearly with the edge radius of worn drills for both materials. The predicted thrust force curves are in very good agreement with the measured curves during the entire process. Average absolute errors of the maximum thrust force for carbon fibre–reinforced plastics and Ti-6Al-4V alloy are 3.24% and 1.88%, respectively.

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