Study of drilling of multi-material (CFRP/Al) using Taguchi and statistical techniques

Abstract

The thrust force and surface roughness of plain carbide drill (K20) with drill parameters (drill diameter, spindle speed and feed rate) in drilling carbon fibre reinforced plastic (CFRP) laminate/aluminum (Grade 2024) stack was experimentally investigated in this study. A L27 orthogonal array and signal-to-noise (S/N) were employed to analyze the effect of drill parameters. Using Taguchi method for design of a robust experiment, the interactions among factors are also investigated. The analysis of variance (ANOVA) shows that the feed rate and drill diameter are the most significant parameters to the overall performance while drilling CFRP/al stack. These results are in good agreement with Signal/Noise (S/N) ratio of Taguchi analysis. Hole diameter of CFRP is found to be less (10μm) than the nominal diameter of drill. Circularity is found to be around 6μm at low feed rates in CFRP. When the feed is increased, the circularity increases to 25 μm.

Keywords

• Drilling, composite/aluminum, ANOVA, experimental design, quality of hole

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