Abstract
A study of drilling uni-directional carbon/epoxy (C/E) composite, a difficult-to-machine material, has been carried out to reveal the formation mechanism of drilling-induced surface damages. A theoretical analysis is reported, which shows that the drilling damages mostly occur in the areas where the fibre orientation angle is in the range of 0°–90°, especially in the vicinity of 6°. To minimise the damages, drilling tools with electroplated diamond abrasives are used to drill the C/E composite. Experimental results with these drills show that the thrust force decreased by 30%–50% while drilling damages at the exit side are also significantly reduced when comparing to drilling with traditional carbide twist drills.
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