The mechanism in drilling carbon fiber reinforced plastic (CFRP) and titanium stack materials differs from that in drilling single material. Titanium chips evacuation through the hole deteriorates the CFRP hole quality. To investigate the quality characteristics of CFRP-layer in drilling of CFRP/Ti stacks, orthogonal experiments are designed for analyzing the effects of both titanium chips and cutting parameters on drilling performance of CFRP-layer. The thrust force, torque and titanium chip morphology are firstly observed. Then the mechanism of hole diameter out of tolerance and entrance spalling is studied. The results show that, with higher feed rate, titanium chips with high temperature and high hardness cause catastrophic erosion of the CFRP-layer, resulting in hole diameter out of tolerance, and increase of entrance spalling. The entrance spalling occurs when the cutting direction and the fibers create a 45 ° angle. Low cutting speed is not suitable for CFRP-layer machining, which worsens the entrance spalling. Therefore, low feed rate and high cutting speed are recommended for drilling of titanium and CFRP layers respectively. Under the premise of enough strength, the drill with larger chip flute is recommended.
NAN Chenggen
,
WU Dan
,
MA Xinguo
,
CHEN Ken
. Study on the Drilling Quality of Carbon Fiber Reinforced Plastic and Titanium Stacks[J]. Journal of Mechanical Engineering, 2016
, 52(11)
: 177
-185
.
DOI: 10.3901/JME.2016.11.177
[1] RAMULU M,BRANSON T,KIM D. A study on the drilling of composite and titanium stacks[J]. Composite Structures,2001,54(1)：67-77.
[2] BRINKSMEIER E,JANSSEN R. Drilling of multi-layer composite materials consisting of carbon fiber reinforced plastics (CFRP),titanium and aluminum alloys[J]. CIRP Annals-Manufacturing Technology,2002,51(1)：87-90.
[3] KIM D,RAMULU M. Drilling process optimization for graphite/bismaleimide-titanium alloy stacks[J]. Composite Structures,2004,63(1)：101-114.
[4] ZITOUNE R,KRISHNARAJ V,COLLOMBET F. Study of drilling of composite material and aluminium stack[J]. Composite Structures,2010,92(5)：1246-1255.
[5] ZITOUNE R,KRISHNARAJ V,ALMABOUACIF B S,et al. Influence of machining parameters and new nano-coated tool on drilling performance of CFRP/aluminium sandwich[J]. Composites Part B-Engineering,2012,43(3)：1480-1488.
[6] MONTOYA M,CALAMAZ M,GEHIN D,et al. Evaluation of the performance of coated and uncoated carbide tools in drilling thick CFRP/aluminium alloy stacks[J]. The International Journal of Advanced Manufacturing Technology,2013,68(9-12)：2111-2120.
[7] PARK K,BEAL A,KIM D D,et al. Tool wear in drilling of composite/titanium stacks using carbide and polycrystalline diamond tools[J]. Wear,2011,271(11-12)：2826-2835.
[8] PARK K,BEAL A,DAE-WOOK KIM D,et al. A comparative study of carbide tools in drilling of CFRP and CFRP-Ti stacks[J]. Journal of Manufacturing Science and Engineering,2013,136(1)：14501.
[9] SHYHA I S,SOO S L,ASPINWALL D K,et al. Hole quality assessment following drilling of metallic-composite stacks[J]. International Journal of Machine Tools & Manufacture,2011,51(7-8)：569-578.
[10] MATSUMURA T,TAMURA S. Cutting force model in drilling of multi-layered materials[J]. Procedia CIRP,2013,8：182-187.
[11] SENTHILKUMAR M,PRABUKARTHI A,KRISHNARAJ V. Study on tool wear and chip formation during drilling carbon fiber reinforced polymer (CFRP)/titanium alloy (Ti6Al4V) stacks[J]. Procedia Engineering,2013,64：582-592.
[12] MONTOYA M,CALAMAZ M,GEHIN D,et al. Numerical simulation of workpiece thermal field in drilling CFRP/aluminum alloy[J]. Key Engineering Materials, 2014,611-612：1226-1235.
[13] PECAT O,BRINKSMEIER E. Low damage drilling of CFRP/titanium compound materials for fastening[J]. Procedia CIRP,2014,13：1-7.
[14] WANG X,KWON P Y,STURTEVANT C,et al. Comparative tool wear study based on drilling experiments on CFRP/Ti stack and its individual layers[J]. Wear,2014,317(1-2)：265-276.
[15] 姜云鹏,张庆茂,王毅,等. 复合材料层合板开口翻边补强试验和数值研究[J]. 复合材料学报,2005,22(5)：190-196.
JIANG Yunpeng,ZHANG Qingmao,WANG Yi,et al. Experiment studies and FEM simulation of repaired composite laminates[J]. Acta Materiae Composite Sinica,2005,22(5)：190-196.
[16] 刘胜. 钛合金正交切削的温度场和切削力仿真与试验研究[D]. 南京：南京航空航天大学,2007.
LIU Sheng. Cutting temperature and force in orthogonal cutting of titanium alloys[D]. Nanjing：Nanjing University of Aeronautics and Astronautics,2007.
[17] TSAO C C,HOCHENG H. Effects of exit back-up on delamination in drilling composite materials using a saw drill and a core drill[J]. International Journal of Machine Tools and Manufacture,2005,45(11)：1261-1270.
[18] CHEN W. Some experimental investigations in the drilling of carbon fiber-reinforced plastic (CFRP) composite laminates[J]. International Journal of Machine Tools and Manufacture,1997,37(8)：1097-1108.
[19] 沈观林,胡更开,刘彬. 复合材料力学[M]. 北京：清华大学出版社,2013.
SHEN Guanlin,HU Gengkai,LIU Bin. Mechanics of composite materials[M]. Beijing：Tsinghua University Press,2013.
