Development of the Hole Generation Technology for Aircraft CFRP Parts

Carbon fiber-reinforced plastics (CFRP), which are now used in some aerospace applications, is difficult to cut and drill holes in. Moreover, no reports have focused on selecting a suitable drilling method for each aerospace part. This paper discusses many methods of hole generation for CFRP composites, including methods using traditional drill tools and non-traditional methods such as abrasive water jet (AWJ), laser beam and abrasive blast. We look at traditional cemented carbide material tools, polycrystalline diamond (PCD) tools, diamond-like carbon (DLC) coated tools and ceramic tools. Then, comparing the experimental results of these methods from the viewpoints of characteristics, efficiency, cost, and hole quality, we investigate each problem to select the suitable drilling method. As a result, we propose a novel method to strategically obtain the best solutions to generate holes in aerospace parts.

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Effects of Nano Organoclay and Wax on the Machining Temperature and Mechanical Properties of Carbon Fiber Reinforced Plastics (CFRP)

Journal of Composites Science ◽

10.3390/jcs3030085 ◽

2019 ◽

Vol 3 (3) ◽

pp. 85 ◽

Cited By ~ 1

Author(s):

El-Ghaoui ◽

Chatelain ◽

Ouellet-Plamondon ◽

Mathieu

Keyword(s):

Mechanical Properties ◽

Carbon Fiber ◽

Polycrystalline Diamond ◽

Fiber Reinforced ◽

Cfrp Laminates ◽

Carbon Fiber Reinforced Plastics ◽

Reinforced Plastics ◽

Fiber Reinforced Plastics ◽

Carbon Fiber Reinforced ◽

Pcd Tools

Carbon fiber reinforced plastics (CFRP) are appreciated for their high mechanical properties and lightness. Due to their heterogeneous nature, CFRP machining remains delicate. Damages are caused on the material and early tool wear occurs. The present study aims to evaluate the effects of fillers on CFRP machinability and mechanical behavior. CFRP laminates were fabricated by the vacuum assisted resin transfer molding (VARTM) process, using a modified epoxy resin. Three fillers (organoclay, hydrocarbon wax, and wetting agent) were mixed with the resin prior to the laminate infusion. Milling tests were performed with polycrystalline diamond (PCD) tools, equipped with thermocouples on their teeth. Machinability was then studied through the cutting temperatures and forces. Tensile, flexural, and short-beam tests were carried out on all samples to investigate the effects of fillers on mechanical properties. Fillers, especially wax, allowed us to observe an improvement in machinability. The best improvement was observed with 1% wax and 2% organoclay, which allowed a significant decrease in the cutting forces and the temperatures, and no deteriorations were seen on mechanical properties. These results demonstrate that upgrades to CFRP machining through the addition of nanoclays and wax is a path to explore.

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Optimization of Machining Parameters in CFRP/Ti Stacks Drilling

ASME 2012 International Manufacturing Science and Engineering Conference ◽

10.1115/msec2012-7216 ◽

2012 ◽

Cited By ~ 2

Author(s):

V. Krishnaraj ◽

A. Prabukarthi ◽

M. Santhosh ◽

M. Senthilkumar ◽

R. Zitoune

Keyword(s):

Quality Parameters ◽

Hole Diameter ◽

Machining Parameters ◽

Hole Quality ◽

Drilling Force ◽

Reinforced Plastics ◽

Weighted Sum Method ◽

Aerospace Applications ◽

Drill Holes ◽

Exit Burr

Carbon fibre reinforced plastics (CFRP) and titanium (Ti) stacks have been steadily replacing metals as choice for engineering materials in aerospace applications. Although materials can be manufactured separately and stacked together to attain a near-net shape, it still involves post processing operations such as trimming and drilling. In order to drill holes efficiently without defects (delamination, circularity, variation in hole diameter) in the CFRP/Ti stacks, it is essential to understand the machining behavior of stacks. An experimental study on the drilling of CFRP/Ti stacks was conducted using K20 carbide drill. The drilling characteristics were evaluated for drilling force and torque, delamination in CFRP, drilled-hole quality (hole diameter and circularity) and exit burr height in Ti. This paper describes an attempt made to maximize the hole quality parameters by employing multi-objective optimization using weighted sum method.

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Characteristics of Acoustic Emission Signals in Machining Using Diamond Coated Tools

ASME 2008 International Manufacturing Science and Engineering Conference, Volume 2 ◽

10.1115/msec_icmp2008-72507 ◽

2008 ◽

Cited By ~ 1

Author(s):

Jianwen Hu ◽

Feng Qin ◽

Kevin Chou ◽

Raymond G. Thompson

Keyword(s):

Acoustic Emission ◽

Cutting Tools ◽

Polycrystalline Diamond ◽

High Strength ◽

Cost Effective ◽

Fast Fourier Transformation ◽

Coated Tools ◽

Coating Delamination ◽

Pcd Tools ◽

Ae Signals

Diamond coated cutting tools have been pursued as a cost-effective substitute to brazed polycrystalline diamond (PCD) tools in applications such as machining high-strength and lightweight materials. However, coating delamination has been known as the major failure mode of diamond coated tools, which terminates tool life prematurely. Once delamination failure occurs, the tool substrate often subjects to severe abrasive wear leading to catastrophic tool failures that imparts the part quality and interrupts machining operations. Hence, accurate detections and forecasts of coating delamination events can prevent production loss and assist process planning. In this study, the characteristics of acoustic emission (AE) signals when machining a high-strength aluminum alloy and a composite using diamond coated cutting tools were investigated. The AE signals were analyzed in both time and frequency domains at various machining conditions and different cutting times. It was found that AE root-mean-square values decrease considerably once coating delamination occurs. The results also indicate a correlation between the tool condition and fast Fourier transformation (FFT) spectra of AE raw data. In addition, the machining experiments implied that it may be feasible to use AE signals to monitor the condition of diamond coated tools during machining.

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Performance of Cutting Tools in High Speed Milling of SiCp/Al Composites

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.591-593.311 ◽

2012 ◽

Vol 591-593 ◽

pp. 311-314 ◽

Cited By ~ 1

Author(s):

Yang Jun Wang ◽

Ming Qiang Pan ◽

Tao Chen ◽

Ji Zhu Liu ◽

Li Guo Chen

Keyword(s):

High Speed ◽

Cutting Temperature ◽

Cutting Speed ◽

Chemical Vapor ◽

Polycrystalline Diamond ◽

Cvd Diamond ◽

Optical Microscope ◽

Coated Tools ◽

Tools Wear ◽

Pcd Tools

This paper presents an experimental study in milling of SiCp/Al composites on a high precision machine by using chemical vapor deposition(CVD) diamond coated tools and polycrystalline diamond (PCD) tools. The tool wear was observed and measured by an optical microscope and a scanning electron microscope (SEM). The results show that the coating rupture causes the failure of the CVD diamond coated tools. The PCD tools’ wear is less. At the relatively low cutting speed, the wear pattern of PCD tools is the flank wear which caused by the abrasion of SiC particles. Due to the low cutting temperature, the graphitization of PCD tools does not happen. The wear mechanism of PCD tools will be the abrasive and adhesive wear.

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Comparison of Ground and Laser Machined Polycrystalline Diamond (PCD) Tools in Cutting Carbon Fiber Reinforced Plastics (CFRP) for Aircraft Structures

Procedia CIRP ◽

10.1016/j.procir.2012.04.031 ◽

2012 ◽

Vol 1 ◽

pp. 178-183 ◽

Cited By ~ 28

Author(s):

Claus Dold ◽

Marcel Henerichs ◽

Lennart Bochmann ◽

Konrad Wegener

Keyword(s):

Carbon Fiber ◽

Polycrystalline Diamond ◽

Fiber Reinforced ◽

Aircraft Structures ◽

Carbon Fiber Reinforced Plastics ◽

Reinforced Plastics ◽

Fiber Reinforced Plastics ◽

Carbon Fiber Reinforced ◽

Pcd Tools

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The Performance of Polycrystalline Diamond (PCD) Tools Machined by Abrasive Grinding and Electrical Discharge Grinding (EDG) in High-Speed Turning

Journal of Manufacturing and Materials Processing ◽

10.3390/jmmp5020034 ◽

2021 ◽

Vol 5 (2) ◽

pp. 34

Author(s):

Guangxian Li ◽

Ge Wu ◽

Wencheng Pan ◽

Rizwan Abdul Rahman Rashid ◽

Suresh Palanisamy ◽

...

Keyword(s):

Electrical Discharge ◽

High Speed ◽

Flank Wear ◽

Polycrystalline Diamond ◽

Machining Efficiency ◽

Crater Wear ◽

Wear Process ◽

High Speed Turning ◽

Tools Wear ◽

Pcd Tools

Polycrystalline diamond (PCD) tools are widely used in industry due to their outstanding physical properties. However, the ultra-high hardness of PCD significantly limits the machining efficiency of conventional abrasive grinding processes, which are utilized to manufacture PCD tools. In contrast, electrical discharge grinding (EDG) has significantly higher machining efficiency because of its unique material removal mechanism. In this study, the quality and performance of PCD tools machined by abrasive grinding and EDG were investigated. The performance of cutting tools consisted of different PCD materials was tested by high-speed turning of titanium alloy Ti6Al4V. Flank wear and crater wear were investigated by analyzing the worn profile, micro morphology, chemical decomposition, and cutting forces. The results showed that an adhesive-abrasive process dominated the processes of flank wear and crater wear. Tool material loss in the wear process was caused by the development of thermal cracks. The development of PCD tools’ wear made of small-sized diamond grains was a steady adhesion-abrasion process without any catastrophic damage. In contrast, a large-scale fracture happened in the wear process of PCD tools made of large-sized diamond grains. Adhesive wear was more severe on the PCD tools machined by EDG.

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Electrical Discharge Grinding (EDG) of Polycrystalline Diamond - Effect of Machining Polarity

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1025-1026.628 ◽

2014 ◽

Vol 1025-1026 ◽

pp. 628-632 ◽

Cited By ~ 3

Author(s):

Mohammad Zulafif Rahim ◽

Song Lin Ding ◽

John Mo

Keyword(s):

Electrical Discharge ◽

Complex Geometry ◽

Polycrystalline Diamond ◽

Machining Process ◽

Morphological Examination ◽

Carbon Structure ◽

Finishing Process ◽

Advanced Machining ◽

The Difference ◽

Pcd Tools

Electrical discharge grinding (EDG) is an advanced machining process and can be utilised to fabricate complex geometry of PCD tools. However, the PCD removal mechanism in this process is complicated. This study was carried out to understand the difference in PCD surface structure with difference EDG polarities. The study revealed that the finishing process with negative polarity is the reason for the porous structure on the surface. Further analysis on the chemical element and carbon structure were implemented as the morphological examination of the surface.

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Experimental Investigation on Surface Roughness in Precision Cutting Ti6Al4V Alloy Using Diamond Tools

Materials Science Forum ◽

10.4028/www.scientific.net/msf.800-801.576 ◽

2014 ◽

Vol 800-801 ◽

pp. 576-579

Author(s):

Lin Hua Hu ◽

Ming Zhou ◽

Yu Liang Zhang

Keyword(s):

Surface Roughness ◽

Cutting Speed ◽

Polycrystalline Diamond ◽

Cutting Parameters ◽

Limited Range ◽

Nose Radius ◽

Machined Surface ◽

Machined Surface Roughness ◽

Titanium Alloy Ti6al4v ◽

Pcd Tools

In this work, cutting experiments were carried out on titanium alloy Ti6Al4V by using polycrystalline diamond (PCD) tools to investigate the effects of the tool geometries and cutting parameters on machined surface roughness. Experimental results show machined surface roughness decreases with increases in the flank angle, tool nose radius and cutting speed within a limited range respectively, and begins to increase as the factors reaches to certain values respectively. And machined surface roughness decreases with increases in feed rate and cutting depth respectively.

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