Effect of laminate configuration and feed rate on cutting performance when drilling holes in carbon fibre reinforced plastic composites |
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| Authors: | Islam Shyha Sein Leung Soo David Aspinwall Sam Bradley |
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| Affiliation: | 1. School of Mechanical Engineering, University of Birmingham, Birmingham B15 2TT, UK;2. Composite Research Centre, GKN Aerospace, Isle of Wight PO32 6LR, UK;1. Mechanical Engineering Department, Faculty of Engineering, King Abdulaziz University, P. O. Box 80204, Jeddah 21589, Saudi Arabia;2. Mechanical Design and Production Engineering Department, Faculty of Engineering, Zagazig University, P. O. Box 44519, Zagazig, Egypt;3. Department of Production Engineering and Mechanical Design, Mansoura University, Mansoura, Egypt;1. University of the Basque Country, UPV/EHU, Faculty of Engineering, Department of Mechanical Engineering, Alameda de Urquijo s/n, 48013 Bilbao, Bizkaia, Spain;2. University of the Basque Country, UPV/EHU, Faculty of Engineering, Department of Applied Mathematics, Alameda de Urquijo s/n, 48013 Bilbao, Bizkaia, Spain;3. I2M, Université de Bordeaux, Arts et Métiers ParisTech, Talence, France;4. IKERBASQUE, Basque Foundation for Science, Bilbao, Spain;1. Aalen University of Applied Sciences, Materials Research Institute, Aalen, Germany;2. Ulm University of Applied Sciences, Institute of Production Engineering and Materials Testing, Ulm, Germany;1. Dept of mechanical engineering, ISM Dhanbad 826004, India |
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| Abstract: | Composites use in the aerospace industry is expanding, in particular carbon fibre reinforced plastics (CFRP) for structural components. Machinability can however be problematic especially when drilling, due to CFRP's inherent anisotropy/in-homogeneity, limited plastic deformation and abrasive characteristics. Following a brief review on composites development and associated machining, the paper outlines experimental results when twist drilling 1.5 mm diameter holes in 3 mm thick CFRP laminate using tungsten carbide (WC) stepped drills. The control variables considered were prepreg type (3 types) and form (unidirectional (UD) and woven), together with drill feed rate (0.2 and 0.4 mm/rev). A full factorial experimental design was used involving 12 tests. Response variables included the number of drilled holes (wear criterion VBBmax ≤ 100 μm), thrust force and torque, together with entry and exit delamination (conventional and adjusted delamination factor values calculated) and hole diameter. Best results were obtained with woven MTM44-1/HTS oven cured material (3750 holes) while the effect of prepreg form on tool life was evident only when operating at the higher level of feed rate. Thrust forces were typically under 125 N with torque values generally below 65 Nmm over the range of operating parameters employed. Finally, the delamination factor (Fd) measured at hole entry and exit ranged between ～1.2–1.8 and 1.0–2.1 respectively. |
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