Investigation of the Effects of Drill Point Angle on Thrust Force (Fz) and Tool Wear in CFRP/Al Stacked Drilling

Year 2019, , 1574 - 1583, 01.09.2019

Erman Aydın

https://doi.org/10.21597/jist.521218

Cited By: 3

Abstract

In this study, the drillability of CFRP/Al stacked structure, which is widely used in military and civil aviation industry, has been investigated with different drill point angles. Drilling operations were performed by direct drilling method with uncoated carbide drills, 30º helix angle and 120º-130º-140º point angles. The experiments were carried out at constant cutting speed of 50 m min-1 and 0.05 mm rev-1 feed without using cutting fluid. Thrust force (Fz) values and tool wear values obtained during drilling operations were examined. Uncoated carbide drills gave similar results in terms of chip structure, while thrust values were lower in 130º point angle drill. In drilling operations at lower thrust forces, tool wear was also occurred less. As a result of the study, it was seen that the uncoated carbide 130º point angle drill compared to 120º and 140º point angle drills has the best results in both thrust force and tool wear in drilling of CFRP/Al stacked structure in this experimental conditions.

Keywords

Al7075, CFRP, CFRP/Al drilling, thrust force, tool wear

CFRP/Al İstifli Delmede Matkap Uç Açısının İtme Kuvveti (Fz) ve Takım Aşınması Üzerine Etkilerinin Araştırılması

Abstract

Bu çalışmada günümüz askeri ve sivil havacılık endüstrisinde yoğun olarak kullanılmakta olan CFRP/Al istifli yapının farklı matkap uç açıları ile delinebilirliği araştırılmıştır. Delme işlemleri 30º helis açılı ve 120º-130º-140º farklı uç açısındaki kaplamasız karbür matkaplar ile doğrudan delme yönteminde, 50m dk-1 sabit kesme hızı, 0.05mm dev-1 ilerleme değerlerinde kesme sıvısı kullanılmadan gerçekleştirilmiştir. Delme işlemleri neticesinde elde edilen Fz değerleri ve matkaplardaki aşınmalar incelenmiştir. Kaplamasız karbür matkaplar talaş yapıları bakımından benzer sonuçlar verirken itme kuvveti değerleri 130º uç açılı matkapta daha düşük elde edilmiştir. Daha düşük kuvvetlerde gerçekleşen delme işlemlerinde, matkap aşınmaları da daha az meydana gelmiştir. Çalışma neticesinde kaplamasız karbür 130º uç açılı matkabın doğrudan delme yönteminde CFRP/Al istifli yapının delinmesinde hem takım aşınması hem de Fz bakımından 120º ve 140º uç açılı matkaplara kıyasla daha iyi sonuçlar verdiği görülmüştür.

Keywords

Al7075, CFRP, CFRP/Al delme, itme kuvveti, takım aşınması

References

• Anonymous: Composites in the airframe and primary structure, http://www.boeing.com/commercial/aeromagazine/articles/qtr_4_06/article_04_2.html Erişim Tarihi: 01.02.2019
• Bağcı E, Özçelik B, 2006. Investigation of the effect of drilling conditions on the twist drill temperature during step-by-step and continuous dry drilling. Materials & Design, 27: 446-454.
• Bayraktar Ş, 2018. Elyaf takviyeli polimer kompozit malzemelerin farklı delme yöntemleri ile delinmesinde kesme performansının değerlendirilmesi: Literatür Taraması. Gazi Üniversitesi Mühendislik-Mimarlık Fakültesi Dergisi, 33 (2), 629-648.
• Brinksmeier E, Janssen R, 2002. Drilling of Multi-Layer Composite Materials consisting of Carbon Fiber Reinforced Plastics (CFRP), Titanium and Aluminum Alloys. CIRP Annals, 51(1): 87-90, ISSN 0007-8506
• Feito N, Díaz-Álvarez J, Díaz-Álvarez A, Cantero J.L, Miguélez M. H, 2014. Experimental Analysis of the Influence of Drill Point Angle and Wear on the Drilling of Woven CFRPs. Materials, 7(6), 4258–4271.
• Fernandez J. Cantero J.L, Diaz J, Miguelez M.H, 2017. Influence of cutting parameters on tool wear and hole quality in composite aerospace components drilling. Composite Structures, 178: 157-161.
• Gaugel S, Sripathy P, Haeger A, Meinhard D, Mernthaler T, Lissek F, Kaufeld M, Knoblauch V, Schneider G, 2016. A comparative study on tool wear and laminate damage in drilling of carbon-fiber reinforced polymers (CFRP). Composite Structures, 155: 173-183.
• Heisel U, Pfeifroth T, 2012. Influence of Point Angle on Drill Hole Quality and Machining Forces When Drilling CFRP, Procedia CIRP, 1: 471-476.
• Hussain S.A, Pandurangadu V, Kumar K.P, 2011. Machinability of glass fiber reinforced plastic (GFRP) composite materials. Science and technology, 3(4): 130-118.
• Islam S, 2010. Drilling of carbon fibre reinforced plastic composites. School of Mechanical Engineering, The University of Birmingham, Doctor of Philosophy (Printed).
• Kaplan Y, 2010. Delik delmede farklı parametrelerin kesme kuvveti, moment, titreşim, yüzey pürüzlülüğü, aşınma ve çapak oluşumuna etkisi. Gazi Üniversitesi Fen Bilimleri Enstitüsü, Yüksek Lisans tezi (Basılmış).
• Kelly J.F, Cotterell M.G, 2002. Minimum lubrication machining of aluminium alloys. Journal of Materials Processing Technology, 120: 327-334.
• Kuo C.L, Soo S.L, Aspinwall D.K, Car C, Bradley S, M’Saoubi R, Leahy W, 2018. Development of single step drilling technology for multilayer metallic-composite stack using uncoated and PVD coated carbide tools. Journal of Manufacturing Processes, 31: 286-300.
• Lin S.C, Chen I.K, 1995. Drilling carbon fiber-reinforced composite material at high speed, An International Journal on the Science and Technology of Friction, Lubrication and Wear, 194: 156-162.
• Marques A.T., Durão L.M., Magalhães A.G., Silva J.F, Tavares J.M.R.S., 2009. Delamination analysis of carbon fibre reinforced laminates: Evaluation of a special step drill. Composites Science and Technology, 69 (14): 2376-2382, ISSN 0266-3538
• Miguel P, Goncalves JS, Tavares RS, Albuquerque C, Aguiar A, Torres A, 2010. Drilling tool geometry evaluation for reinforced composite laminates. Composite Structer, 92: 1545–1550.
• Nouari M, List G, Girot F, Gehin D, 2005. Effect of machining parameters and coating on wear mechanism in dry drilling of aluminium alloys. International Journal of Machine Tools & Manufacture, 45: 1436-1442.
• Rawat S, Attia H, 2009. Wear mechanisms and tool life management of WC–Co drills during dry high speed drilling of woven carbon fibre composites. Wear, 267 (5-8): 1022-1030.
• Rivero A, Aramendi G, Herranz S, Lacalle L.N, 2006. An experimental investigation of the effect of coating and cuttinh parameters on the dry drilling performance of aluminium alloys. international journal advanced manufacture technology, 28: 1-11.
• Romoli L., Lutey, A.H.A. (2019). Quality monitoring and control for drilling of CFRP laminates. Journal of Manufacturing Processes, 40, 16-26.
• Sheikh-Ahmed J.Y, 2009. Machining of polymer composites. Springer, pp: 1-137, 187-208, DOI:10.1007/978-0-387-68619-6, New York, USA.
• Soutis C, 2005. Carbon fiber reinforced plastics in aircraft construction. Materials Science and Engineering, 412 (1-2): 171-176.
• Wang D.H, Ramulu M, Arola D, 1995. Orthogonal cutting mechanisms of graphite/epoxy composite. Part I: unidirectional laminate. International Journal of Machine Tools and Manufacture, 35 (12): 1623-1638, ISSN: 0890-6955.
• Wang X, Kwon Y.P, Sturtevant Kim, D.C, Lantrip J, 2012. Tool wear of coated drills in drilling CFRP. Journal of Manufacturing Processes, 15: 127-135.
• Yaşar N, Günay M, 2019. Experimental investigation on novel drilling strategy of CFRP laminates using variable feed rate. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 41 (3): 150.
• Yaşar N, Korkmaz M.E, Günay M, 2017. Investigation on hole quality of cutting conditions in drilling of CFRP composite. In MATEC Web of Conferences, 112: 01013.
• Zitoune R, Krishnaraj V, Coolombet F, 2010. Study of drilling of composite material and aluminium stack. Composite Structures, 92: 1246-1265.
• Zitoune R, Krishnaraj V, Almabouacif B.S, Collombet F, Sima M, Jolin A, 2012. Influence of machining parameters and new nano-coated tool on drilling performance of CFRP/Aluminium sandwich. Composites, 43: 1480-1488.
• Zitoune R, Krishnara V. J, Coolombet F, Le Roux S, 2016. Experimental and numerical analysis on drilling of carbon fibre reinforced plastic and aluminium stack. Composite Structures, 146: 148-158.