Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber reinforced plastics

doi:10.1007/s11465-020-0598-y

Front. Mech. Eng.

2020, Vol. 15

Issue (4) : 538-546 https://doi.org/10.1007/s11465-020-0598-y

RESEARCH ARTICLE

Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber reinforced plastics

Guofeng MA, Renke KANG, Zhigang DONG(

), Sen YIN, Yan BAO, Dongming GUO

Key Laboratory for Precision and Non-Traditional Machining of Ministry of Education, Dalian University of Technology, Dalian 116024, China

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Abstract

Carbon fiber reinforced plastic (CFRP) composites are extremely attractive in the manufacturing of structural and functional components in the aircraft manufacturing field due to their outstanding properties, such as good fatigue resistance, high specific stiffness/strength, and good shock absorption. However, because of their inherent anisotropy, low interlamination strength, and abrasive characteristics, CFRP composites are considered difficult-to-cut materials and are prone to generating serious hole defects, such as delamination, tearing, and burrs. The advanced longitudinal–torsional coupled ultrasonic vibration assisted drilling (LTC-UAD) method has a potential application for drilling CFRP composites. At present, LTC-UAD is mainly adopted for drilling metal materials and rarely for CFRP. Therefore, this study analyzes the kinematic characteristics and the influence of feed rate on the drilling performance of LTC-UAD. Experimental results indicate that LTC-UAD can reduce the thrust force by 39% compared to conventional drilling. Furthermore, LTC-UAD can decrease the delamination and burr factors and improve the surface quality of the hole wall. Thus, LTC-UAD is an applicable process method for drilling components made with CFRP composites.

Keywords longitudinal–torsional coupled ultrasonically drilling CFRP thrust force hole quality

Corresponding Author(s): Zhigang DONG

Just Accepted Date: 16 September 2020 Online First Date: 29 October 2020 Issue Date: 02 December 2020

Cite this article:

Guofeng MA,Renke KANG,Zhigang DONG, et al. Hole quality in longitudinal–torsional coupled ultrasonic vibration assisted drilling of carbon fiber reinforced plastics[J]. Front. Mech. Eng., 2020, 15(4): 538-546.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-020-0598-y
https://academic.hep.com.cn/fme/EN/Y2020/V15/I4/538

Fig.1 Schematics of (a) CD, (b) L-UAD and (c) LTC-UAD.

Fig.2 Trajectories of optional point on the main cutting edge of the drill in (a) CD, (b) L-UAD, and (c) LTC-UAD.

Fig.3 Experimental (a) schematic and (b) setup of UAD.

Fig.4 (a) L-vibration unit and (b) LTC-vibration unit.

Fig.5 CFRP composites plate.

Tab.1 Material physical properties of the T800 CFRP unidirectional plate [²⁷]

Fig.6 Schematics of (a) delamination factor (F_D) and (b) burr factor (F_B).

Tab.2 Experimental parameters

Fig.7 Thrust forces vs. time for CD, L-UAD, and LTC-UAD (n = 2000 r/min, F = 0.005 mm/r).

Fig.8 Effect of feed rate on the thrust force in CD, L-UAD and LTC-UAD of CFRP.

Fig.9 Effect of feed rate on the delamination factors of hole exit by CD, L-UAD, and LTC-UAD.

Fig.10 Effect of feed rate on the burr factors of hole exit by CD, L-UAD, and LTC-UAD.

Fig.11 Effect of feed rate on the surface roughness of the hole wall drilled by CD, L-UAD and LTC-UAD.

Fig.12 SEM images of CFRP hole wall drilled by (a) CD, (b) L-UAD, (c) LTC-UAD (n = 2000 r/min, F = 0.005 mm/r, 500×).

Fig.13 SEM images of CFRP hole wall drilled by (a) CD, (b) L-UAD, (c) LTC-UAD (n = 2000 r/min, F = 0.005 mm/r, 3000×).

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