Effect of tool wear on drilling unidirectional CFRP laminates in different fiber cutting angles
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ORIGINAL ARTICLE
Effect of tool wear on drilling unidirectional CFRP laminates in different fiber cutting angles Zhen-yuan Jia 1 & Yu Bai 1 & Fu-ji Wang 1 & Jia-xuan Hao 1 Received: 5 January 2020 / Accepted: 3 August 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Drilling performance of carbon fiber reinforced polymer (CFRP) aggravates significantly with serious tool wear caused by highly abrasive fibers. Because of the anisotropy of CFRP, the angle between fiber orientation and cutting direction, namely, fiber cutting angle, also plays a crucial part in the drilling performance. To enhance drilling performance, this paper initially conducts a comprehensive experimental study on the effects of tool wear on thrust force, exit temperature, and hole wall defect in different fiber cutting angles in the drilling of unidirectional CFRP. The results demonstrate that the profile of worn cutting edge is an approximate elliptical arc and the half axis lengths of the elliptical arc are utilized to evaluate cutting edge wear. Tool wear on the cutting edge, flank face, and rake face all deteriorates with the number of drilled holes. Tool wear has a more significant influence on thrust force in the fiber cutting angle region of 0~90° than in the fiber cutting angle region of 90~180°. With increasing tool wear, the exit temperature distribution can still be approximate to an ellipse. The variation of exit temperature caused by tool wear in the major axis direction is still no less than that in other directions. In addition, on hole wall, tool wear causes severe crack defects in the fiber cutting angle region of 0~90° and cavity defects in the fiber cutting angle region of 90~180°. Keywords CFRP . Tool wear . Fiber cutting angle . Thrust force . Exit temperature . Hole wall defect
1 Introduction In aircraft industry, the demand for high-performance and lightweight components has increased substantially to enhance the bearing capacity of airplane. Due to the outstanding properties, numerous carbon fiber reinforced polymers (CFRP) have been widely employed in the aircraft parts [1, 2]. In order to realize the tremendous amounts of connections and assemblies among CFRP parts, the drilling process is inevitable [3]. However, the highly abrasive fiber will scratch tool surface and cause severe tool wear in the drilling of CFRP [4]. The serious tool wear remarkably deteriorates the drilling performance that plays a crucial part in the service performance of CFRP parts [5, 6]. Therefore, to ensure the reliable
* Fu-ji Wang [email protected] 1
Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education, School of Mechanical Engineering, Dalian University of Technology, Dalian 116024, China
operation of CFRP parts, it is urgently needed to clarify the effect of tool wear on drilling CFRP. Numerous researches have been conducted on the effect of tool wear on drilling CFRP at present. Most of them were carried out by adopting the research approach in metal processing a
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