Multiple Sensor Monitoring of CFRP Drilling to Define Cutting Parameters Sensitivity on Surface Roughness, Cylindricity and Diameter.

Miguel Álvarez-Alcón,Luis Norberto López De Lacalle,Francisco Fernández-Zacarías

doi:10.3390/ma13122796

Miguel Álvarez-Alcón, Luis Norberto López De Lacalle + Show 1 more

Open Access

https://doi.org/10.3390/ma13122796

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Journal: Materials	Publication Date: Jun 21, 2020
Citations: 15	License type: CC BY 4.0

Affiliation: University of Cádiz

Abstract

Machining parameters affects the final quality of components made in carbon fiber reinforced plastic (CFRP) composite materials. In this framework, the work here presented aims at studying the right combination of cutting speed (vc) and feed rate (vf), for dry drilling of carbon fiber reinforced plastic composite materials, which obtained better results regarding roughness, hole cylindricity, and diameter. A series of experimental tests were carried out under different drilling conditions (vc/vf), monitoring the thrust force (Fz), torque (T), and electric power (EP), to define which one can help more for industrial daily life production. Results validation was carried out using the analysis of variance, in order to relate main machining parameters cutting speed and linear feed, with thrust force, drilling torque, main spindle electric power and hole quality parameters (average roughness, cylindricity and diameter). The conclusions show that thrust force is not proportional to the cutting speed and the best combinations of cutting speed and feed were found out around the average values of tested parameters. Spindle electric power is an interesting element to take into account because it is easy to consider in real production.

Highlights

Due to their excellent properties, carbon fiber reinforced plastic (CFRP) composite materials are widely used in strategic sectors such as aeronautics, aerospace, windmill, naval and automotive, among others, where weight reduction, lower consumption and lower impact on environmental impact play important roles [1,2,3]
Once the data acquired by the on-line monitoring systems, of thrust force (Fz), torque (T) and electric power (EP) have been processed and analyzed, and the off-line values of roughness (Ra), diameter measured (D) and cylindricity (C), taken as indicators of hole quality, we proceed to describe the results of the experimental tests
Roughness values of holes are considerably increased by 21–140% and cylindricity are considerably increased by 5–91% under different combinations of vc and vf when compared with vc = 105 m/min and vf = 300 mm/min

Summary

Introduction

Due to their excellent properties, carbon fiber reinforced plastic (CFRP) composite materials are widely used in strategic sectors such as aeronautics, aerospace, windmill, naval and automotive, among others, where weight reduction, lower consumption and lower impact on environmental impact play important roles [1,2,3]. The assembly of different aircraft parts is carried out by means of mechanical unions, such as screws, bolts and rivets, where previously, thousands or millions of holes are required [4,5,6]. Aamir, et al [6] gave a good classification of aspects related to hole drilling quality in CFRP, similar to Figure 1.

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