The Effect of Thrust Force in Drilling Composite Materials Using a New Step Core-Ball Drill

2020 ◽  
Vol 830 ◽  
pp. 77-84
Author(s):  
Hsing Ming Teng ◽  
Ming Chang Wu ◽  
Jin Yi Kao ◽  
Chun Yao Hsu ◽  
Chung Chen Tsao
Keyword(s):  
Composite Materials ◽  
Composite Laminates ◽  
Thrust Force ◽  
Composite Plates ◽  
High Strength ◽  
Tool Geometry ◽  
Lower Weight ◽  
Final Assembly ◽  
Chip Flow ◽  
Metal Materials

Compared with conventional metal materials, composite materials can sustain more loads under lower weight and lower space, which is more suitable to use in high strength environment for structure parts application in aerospace, military, transportation and leisure. The enormous aeronautical components and structures of composite materials require assembly and machining. Drilling is the most important making-hole process in the final assembly. However, conventional drill cannot avoid delamination in drilling composite materials effectively depending on tool geometry only. Delamination caused by drilling thrust has been showed as one of the most problematic defects after drilling composite laminates. Drilling of composite plates using a new step core-ball drill (NSCBD), which is a special drill to improve the chip flow and reduces the thrust force (delamination) at the exit of hole, is studied and compared to the traditional step core-ball drill (TSCBD). The thrust force of new step core-ball drill in drilling composite materials was investigated in this study. The theoretical analysis and experimental results show that the NSCBD can improve the thrust force (delamination) and efficiency than TSCBD in drilling composite materials.

scholarly journals The effect of thrust force in drilling composite materials using step core-ball drill

2018 ◽  
Vol 185 ◽  
pp. 00016
Author(s):  
Hsing-Ming Teng ◽  
Chung-Chen Tsao
Keyword(s):  
Composite Materials ◽  
Composite Laminates ◽  
Thrust Force ◽  
Weight Ratio ◽  
Composite Plates ◽  
High Strength ◽  
Tool Geometry ◽  
Machining Parameters ◽  
Chip Flow ◽  
Hole Making

Composite materials have gained increasing popularity over the past few decades due to their superior mechanical properties, such as high strength-to-weight ratio, fighting against high temperature and corrosion resistance. The assembly of enormous aeronautical components and structures require the machining of composite materials. Drilling is the most important hole-making process in the final assembly. When drilling composite materials, a number of defects are generating. Delamination caused by drilling thrust has been showed as one of the most problematic defects after drilling composite laminates. With a pressing need for decreased delamination, many studies are turning more and more toward tool geometry and machining parameters. Drilling of composite plates using a step core-ball drill, which is a special drill to improve the chip flow and reduces the thrust force at the exit of hole, is investigated in this study. The experimental results found that the step core-ball drill was efficient in drilling of carbon fiber reinforced plastic (CFRP) and did not produce loading on the drill exit at the proper drilling conditions. The results obtained from this study feeding back for fundamental research efforts could steer future studies on the drilling composite materials in the most promising direction.

Experimental Analysis for the Effect of Impactor Geometry on Carbon Reinforced Composite Materials

2017 ◽  
Vol 25 (9) ◽  
pp. 677-682 ◽  
Author(s):  
Faruk Elaldi ◽  
Busra Baykan ◽  
Can Akto
Keyword(s):  
Composite Materials ◽  
Carbon Fibre ◽  
Composite Plates ◽  
High Strength ◽  
Low Velocity Impact ◽  
Low Velocity ◽  
Damage Area ◽  
Reinforced Composite ◽  
Contact Surfaces ◽  
The Impact

For the last three decades, composites have become very preferable materials to be used in the automotive industry, structural parts of aircraft and military systems and spacecraft, due to their high strength and modulus. Composite materials are sometimes exposed to invisible or visible damage due to impact loading during their service life. In this study, the effect of impactor geometry with four different contact surfaces on woven carbon fibre-reinforced composite plates having three different thicknesses are investigated. In the first stage, composite plates were manufactured with the ply orientations of [45/-45/0/90/45/-45]2s, [45/-45/0/90/45/-45]3s, [45/-45/0/90/45/-45]4s based on conventional usage. In the second stage, carbon fibre-reinforced composite test panels were exposed to low velocity impact tests to obtain force-time, energy-time and force-displacement curves. Finally, semi and full penetration of composite panels and damage magnitude were determined. It was found that the impactor geometries with lower contact surfaces such as conical and ogive types were much more penetrative on composite plates than the other geometries, but they caused larger damage area in the vicinity of the impact point.

Delamination-Free Drilling of Composite Laminates

1994 ◽  
Vol 116 (4) ◽  
pp. 475-481 ◽  
Author(s):  
S. Jain ◽  
D. C. H. Yang
Keyword(s):  
Composite Laminates ◽  
Thrust Force ◽  
Tool Geometry ◽  
Elliptical Plate ◽  
Hole Quality ◽  
Drilling Operation ◽  
Twist Drills ◽  
Drill Tool

Composite laminates in significant numbers are rendered unacceptable due to delamination that occurs during the drilling operation. Thrust generated during the drilling operation is identified as responsible for delamination. Expressions developed for critical thrusts and critical feed rates, by modeling the delamination zone as an elliptical plate in unidirectional laminates, appear to be fairly accurate. It has been demonstrated that the critical thrusts and feed rates obtained for unidirectional laminates can be conservatively used for multi-directional laminates. With regard to the tool geometry, the chisel edge width appears to be the single most important factor contributing to the thrust force and hence delamination. A diamond-impregnated tubular drill tool was designed and tested. This tool resulted in a much smaller thrust and much better hole quality as compared with the standard twist drills.

Effects of Feedrate and Chisel Edge on Delamination in Composites Drilling

1993 ◽  
Vol 115 (4) ◽  
pp. 398-405 ◽  
Author(s):  
S. Jain ◽  
D. C. H. Yang
Keyword(s):  
Composite Laminates ◽  
Thrust Force ◽  
Plate Theory ◽  
Tool Geometry ◽  
Laminated Plate ◽  
Elliptical Plate ◽  
Time Optimal ◽  
Critical Thrust Force ◽  
Clamped Edges ◽  
Central Load

Delamination accompanied with the drilling of composite laminates has been recognized as a major problem. An analytical model is established to predict critical thrust force and critical feedrate at which the delamination crack begins to propagate. For unidirectional composites, the delamination zone is modeled as an elliptical plate, with clamped edges and subjected to a central load. Based on fracture mechanics, laminated plate theory and cutting mechanics, expressions are developed for critical thrusts and critical feedrates at which delamination is initiated at different ply locations. This model has been verified by experiments. A variable feedrate strategy is formulated based on this model, which avoids delamination while drilling in a time-optimal fashion. In addition, the need to modify tool geometry to avoid delamination is highlighted. Chisel edge width has been identified as an important factor contributing to the thrust force and hence delamination.

Computerized Tomography and C-Scan for Measuring Drilling-Induced Delamination in Composite Material Using Twist Drill and Core Drill

2007 ◽  
Vol 339 ◽  
pp. 16-20 ◽  
Author(s):  
H. Hocheng ◽  
Chung Chen Tsao
Keyword(s):  
Composite Material ◽  
Composite Materials ◽  
Computerized Tomography ◽  
Cross Section ◽  
Thrust Force ◽  
Design Parameters ◽  
Tool Geometry ◽  
Ultrasonic Technique ◽  
Twist Drill

Delamination is one of the most concern defects in drilling of composite material. Delamination depends on the factors such as feed rate, tool geometry and wear. The mechanics of drilling composite materials has been examined along with the quality of the hole and the effect of tool design parameters. The capacity of computerized tomography (CT) showing sample cross-section in a nondestructive way made it successful in measuring the drilling-induced delamination. In the experiment, the correlation between thrust force and the measured delamination extent in use of twist drill and core drill is illustrated and compared with the known ultrasonic C-scan. It is compared with the ultrasonic technique and is demonstrated a feasible and an effective tool for the evaluation of drilling-induced delamination.

COMPARATIVE CHARACTERISTICS OF PHYSICAL AND MECHANICAL PROPERTIES OF COMPOSITE MATERIALS AND HIGH-STRENGTH STEEL 30FGSN2A

2020 ◽  
Author(s):  
I.R. Antypes ◽  
◽  
V.V. Zaitsev ◽  
Keyword(s):  
Composite Materials ◽  
High Strength Steel ◽  
Critical Stress ◽  
Physical And Mechanical Properties ◽  
High Strength ◽  
Aviation Industry ◽  
Specific Strength ◽  
Aircraft Landing ◽  
Carbon Plastics ◽  
Aircraft Landing Gear

Currently, the use of composite materials is increasingly used in various areas of the national economy, including the aviation industry. The materials of this article are devoted to the study of the use of composite materials for the manufacture of aircraft landing gear in comparison with the traditionally used brand of steel. As a result of the work carried out, it was found that the slope made of carbon fiber showed a critical stress twice as high as its design made of 30xgsn2a steel. In addition, carbon plastics are superior to high-strength steel in terms of specific strength, stiffness, and tensile strength.

Bamboo Waste-based Bio-composite Substance: An application for Low-cost Construction Materials

2020 ◽  
Vol 4 (1) ◽  
pp. 41-48
Author(s):  
Teodoro Astorga Amatosa ◽  
Michael E. Loretero
Keyword(s):  
Composite Materials ◽  
Sea Water ◽  
Raw Materials ◽  
Low Cost ◽  
Construction Materials ◽  
Single Layer ◽  
High Strength ◽  
Green Technology ◽  
Experimental Medium ◽  
Natural Treatment

Bamboo is a lightweight and high-strength raw materials that encouraged researchers to investigate and explore, especially in the field of biocomposite and declared as one of the green-technology on the environment as fully accountable as eco-products. This research was to assess the technical feasibility of making single-layer experimental Medium-Density Particleboard panels from the bamboo waste of a three-year-old (Dendrocalamus asper). Waste materials were performed to produce composite materials using epoxy resin (C21H25C105) from a natural treatment by soaking with an average of pH 7.6 level of sea-water. Three different types of MDP produced, i.e., bamboo waste strip MDP (SMDP), bamboo waste chips MDP (CMDP) and bamboo waste mixed strip-chips MDP (MMDP) by following the same process. The experimental panels tested for their physical-mechanical properties according to the procedures defined by ASTM D1037-12. Conclusively, even the present study shows properties of MDP with higher and comparable to other composite materials; further research must be given better attention as potential substitute to be used as hardwood materials, especially in the production, design, and construction usage.

Physical Ultrasonics of Composites

2011 ◽  
Author(s):  
Dale Chimenti ◽  
Stanislav Rokhlin ◽  
Peter Nagy
Keyword(s):  
Composite Laminates ◽  
Stiffness Matrix ◽  
Composite Plates ◽  
Anisotropic Media ◽  
Anisotropic Materials ◽  
Ultrasonic Waves ◽  
Laminated Plates ◽  
Structure Characteristic ◽  
Major Advance

Physical Ultrasonics of Composites is a rigorous introduction to the characterization of composite materials by means of ultrasonic waves. Composites are treated here not simply as uniform media, but as inhomogeneous layered anisotropic media with internal structure characteristic of composite laminates. The objective here is to concentrate on exposing the singular behavior of ultrasonic waves as they interact with layered, anisotropic materials, materials which incorporate those structural elements typical of composite laminates. This book provides a synergistic description of both modeling and experimental methods in addressing wave propagation phenomena and composite property measurements. After a brief review of basic composite mechanics, a thorough treatment of ultrasonics in anisotropic media is presented, along with composite characterization methods. The interaction of ultrasonic waves at interfaces of anisotropic materials is discussed, as are guided waves in composite plates and rods. Waves in layered media are developed from the standpoint of the "Stiffness Matrix", a major advance over the conventional, potentially unstable Transfer Matrix approach. Laminated plates are treated both with the stiffness matrix and using Floquet analysis. The important influence on the received electronic signals in ultrasonic materials characterization from transducer geometry and placement are carefully exposed in a dedicated chapter. Ultrasonic wave interactions are especially susceptible to such influences because ultrasonic transducers are seldom more than a dozen or so wavelengths in diameter. The book ends with a chapter devoted to the emerging field of air-coupled ultrasonics. This new technology has come of age with the development of purpose-built transducers and electronics and is finding ever wider applications, particularly in the characterization of composite laminates.

scholarly journals Introduction to Macroscopic Optimal Design in the Mechanics of Composite Materials and Structures

2021 ◽  
Vol 5 (2) ◽  
pp. 36
Author(s):  
Aleksander Muc
Keyword(s):  
Composite Materials ◽  
Composite Structures ◽  
Constitutive Relations ◽  
A Priori ◽  
Chemical Properties ◽  
Composite Plates ◽  
Failure Criteria ◽  
Lagrange Equations ◽  
Homogenization Methods ◽  
Mechanics Of Composite Materials

The main goal of building composite materials and structures is to provide appropriate a priori controlled physico-chemical properties. For this purpose, a strengthening is introduced that can bear loads higher than those borne by isotropic materials, improve creep resistance, etc. Composite materials can be designed in a different fashion to meet specific properties requirements.Nevertheless, it is necessary to be careful about the orientation, placement and sizes of different types of reinforcement. These issues should be solved by optimization, which, however, requires the construction of appropriate models. In the present paper we intend to discuss formulations of kinematic and constitutive relations and the possible application of homogenization methods. Then, 2D relations for multilayered composite plates and cylindrical shells are derived with the use of the Euler–Lagrange equations, through the application of the symbolic package Mathematica. The introduced form of the First-Ply-Failure criteria demonstrates the non-uniqueness in solutions and complications in searching for the global macroscopic optimal solutions. The information presented to readers is enriched by adding selected review papers, surveys and monographs in the area of composite structures.

scholarly journals Experimental Investigation on the Influence of Fiber Path Curvature on the Mechanical Properties of Composites

Materials ◽  
2021 ◽  
Vol 14 (10) ◽  
pp. 2602
Author(s):  
Huaqiao Wang ◽  
Jihong Chen ◽  
Zhichao Fan ◽  
Jun Xiao ◽  
Xianfeng Wang
Keyword(s):  
Tensile Strength ◽  
Path Planning ◽  
Composite Laminates ◽  
Bending Strength ◽  
High Strength ◽  
Bending Test ◽  
Fiber Placement ◽  
Automated Fiber Placement ◽  
Fiber Path ◽  
Path Curvature

Automated fiber placement (AFP) has been widely used as an advanced manufacturing technology for large and complex composite parts and the trajectory planning of the laying path is the primary task of AFP technology. Proposed in this paper is an experimental study on the effect of several different path planning placements on the mechanical behavior of laminated materials. The prepreg selected for the experiment was high-strength toughened epoxy resin T300 carbon fiber prepreg UH3033-150. The composite laminates with variable angles were prepared by an eight-tow seven-axis linkage laying machine. After the curing process, the composite laminates were conducted by tensile and bending test separately. The test results show that there exists an optimal planning path among these for which the tensile strength of the laminated specimens decreases slightly by only 3.889%, while the bending strength increases greatly by 16.68%. It can be found that for the specific planning path placement, the bending strength of the composite laminates is significantly improved regardless of the little difference in tensile strength, which shows the importance of path planning and this may be used as a guideline for future AFP process.

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