An Investigation into Tool Wear and Hole Quality during Low-Frequency Vibration-Assisted Drilling of CFRP/Ti6Al4V Stack

The use of lightweight material such as CFRP/Ti6Al4V in stacked structures in the aerospace industry is associated with improved physical and mechanical characteristics. The drilling process of nonuniform structures plays a significant role prior to the assembly operation. However, this drilling pro...

Full description

Saved in:
Bibliographic Details
Published inJournal of Manufacturing and Materials Processing Vol. 3; no. 3; p. 63
Main Authors Hussein, Ramy, Sadek, Ahmad, Elbestawi, Mohamed A., Attia, M. Helmi
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 01.09.2019
Subjects
Aerospace industry
CFRP/Ti6Al4V
Crack initiation
Cutting energy
Cutting wear
Delamination
Drilling
Evacuation
low-frequency vibration-assisted drill
Lubricants & lubrication
Machining
Mechanical properties
Process parameters
Residual stress
stacked material
Stress concentration
surface integrity
Thermal analysis
Thrust
Titanium
Titanium base alloys
Tool wear
Vibration effects
vibration-assisted drilling
Wear mechanisms
Online AccessGet full text

Cover

More Information
Summary:The use of lightweight material such as CFRP/Ti6Al4V in stacked structures in the aerospace industry is associated with improved physical and mechanical characteristics. The drilling process of nonuniform structures plays a significant role prior to the assembly operation. However, this drilling process is typically associated with unacceptable CFRP delamination, hole accuracy, and high tool wear. These machining difficulties are attributed to high thermal load and poor chip evacuation mechanism. Low-frequency vibration-assisted drilling (LF-VAD) is an advanced manufacturing technique where the dynamic change of the uncut chip thickness is used to manipulate the cutting energy. An efficient chip evacuation mechanism was achieved through axial tool oscillation. This study investigates the effect of vibration-assisted drilling machining parameters on tool wear mechanisms. The paper also presents the effect of tool wear progression on drilled hole quality. Hole quality is described by CFRP entry and exit delamination and hole accuracy. The results showed a significant reduction in the thrust force, cutting torque, cutting temperature, and flank wear-land.
ISSN:2504-4494
2504-4494
DOI:10.3390/jmmp3030063