Experimental analysis of special tool geometries when drilling woven and multidirectional CFRPs

Significance Statement

Due to the inherent inhomogeneity and anisotropy of Fiber Reinforced Polymers (FRP) laminates, and to the abrasive properties of the fibers, the damage induced during drilling process can result in the rejection of components and an increase in production cost. Delamination has been identified in the literature as the most detrimental damage phenomenon for structural components as it results in a significant loss of strength and stiffness of the laminate, and consequently its load carrying capacity. Identification and prevention of this phenomenon becomes particularly important for composite components subject to adverse environmental conditions and compressive, shear, and cyclic loads over extended periods of time. Drilling induced damage depends also on several factors such as, drill bit geometry, cutting parameters, and tool wear. This study has been carried out with the main goal of generating new knowledge in the field of carbon fiber composite drilling. Three different drill bit geometries are analyzed studding the influence of the input variables (feed rate and cutting speed) in the cutting forces and in delamination damage. Statistical tools have been used to support this study. The ANOVA study because it offers a complete overview about the influence of the input parameters on cutting forces and delamination. It considers more factors and interactions between the variables than others ANOVA founded in the literature.

 

 

Experimental analysis of special tool geometries when drilling woven and multidirectional CFRPs. Advances in Engineering

Experimental analysis of special tool geometries when drilling woven and multidirectional CFRPs. Advances in Engineering

 

Journal Reference

Journal of Reinforced Plastics and Composites October 22, 2015.

Norberto Feito, Antonio Diaz-Álvarez, José L Cantero, Marcos Rodríguez-Millán, Henar Miguélez 

Department of Mechanical Engineering, Universidad Carlos III de Madrid, Madrid, Spain.

Abstract

Drilling is one of the most frequent machining operations for carbon fiber-reinforced polymer composites, carried out prior to assembly between structural components using mechanical joining. Delamination is the main damage mechanism involved during carbon fiber-reinforced polymer composite drilling causing an elevated percentage of workpiece rejection. Tool geometry strongly influences drilling performance. In this paper, an original work dealing with the comparison between three recently developed configurations (Brad center, Step drill and Reamer drills) in terms of drilling forces and delamination both for woven and tape carbon fiber-reinforced polymers is presented. Reamer drill showed the best results concerning productivity and delamination. Strong differences were found when hole quality obtained in tape and woven composite was compared: multidirectional composite presented poorer hole quality than woven composite under the same cutting conditions. The analysis of variance was developed in order to analyze the influence of each parameter showing the importance of feed rate on surface damage.

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