Abstract
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.
Highlights
Superior physical and mechanical characteristics, such as high strength to weight ratio, low coefficient of thermal expansion, fatigue resistance, and corrosion/erosion resistance [1,2,3], explain the growing usage of carbon fiber reinforced polymers (CFRP) and Ti6Al4V in the aerospace industry
Convenient inspection, and easy detachability are of the main advantages of mechanical fastening that are typically used in the assembly process of different materials in the load carrying members, making the drilling process of CFRP and Ti6Al4V a necessity prior to the assembly process
The conventional drilling process of CFRP is commonly associated with surface integrity defects such as entry and exit delamination and matrix thermal damage [6,7,8,9]
Summary
Superior physical and mechanical characteristics, such as high strength to weight ratio, low coefficient of thermal expansion, fatigue resistance, and corrosion/erosion resistance [1,2,3], explain the growing usage of carbon fiber reinforced polymers (CFRP) and Ti6Al4V in the aerospace industry. The conventional drilling process of CFRP is commonly associated with surface integrity defects such as entry and exit delamination and matrix thermal damage [6,7,8,9]. Poor chip evacuation mechanism, and burr formation are of the common issue during the drilling process of Ti6Al4V [19,20,21].
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