Hybrid processes in manufacturing

Proceedings of world academy of science, engineering and technology, vol 8

Delamination formation, evaluation and suppression during drilling of composite laminates: A review

Drilling carbon fibre reinforced plastics (CFRPs) is typically cumbersome due to high structural stiffness of the composite and low thermal conductivity of plastics. Resin-rich areas between neighbouring plies in a laminate are prone to drilling-induced delamination that compromises structural integrity. Appropriate selection of drilling parameters is believed to mitigate damage in CFRPs. In this context, we study the effect of cutting parameters on drilling thrust force and torque during the machining process both experimentally and numerically. A unique three-dimensional (3D) finite element model of drilling in a composite laminate, accounting for complex kinematics at the drill-workpiece interface is developed. Cohesive zone elements are used to simulate interply delamination in a composite. Experimental quantification of drilling-induced damage is performed by means of X-ray micro computed tomography. The developed numerical model is shown to agree reasonably well with the experiments. The model is used to predict optimal drilling parameters in carbon/epoxy composites.

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Drilling in carbon/epoxy composites: experimental investigations and finite element implementation

Surface morphology assessment of CFRP transverse grinding using CNT nanofluid minimum quantity lubrication

Effect of ultrasonically-assisted drilling on carbon-fibre-reinforced plastics

Machining experiments were conducted to evaluate the impact of cutting parameters on the hole quality and cutting forces in drilling Al2024-T3 aerospace alloy. Al2024-T3 specimen were drilled using Φ6-mm TiAlN-coated carbide twist drills under dry cutting conditions. The hole quality was inspected in terms of its surface roughness, burr and chip formations, hole size, circularity error and post-machining microhardness of the subsurface of the holes. An analysis of variance (ANOVA) was carried out to determine the percentage contribution of cutting parameters on cutting forces and the inspected hole quality parameters. A three-dimensional (3D) finite element (FE) model of drilling Al2024-T3 is developed using Abaqus/Explicit to predict thrust force and torque. The FE model was validated using experimental results and found to be in good agreement. The results of the study showed that the cutting parameters have a significant impact on cutting forces and inspected hole quality parameters. Drilling at feed rates of 100 and 300 mm/min and spindle speeds of 1000, 3000, and 6000 rpm are recommended for producing holes with smaller surface roughness, deviation from nominal hole size, circularity error and burrs.

Assessment of cutting forces and hole quality in drilling Al2024 aluminium alloy: experimental and finite element study

Machining Glass fibre aluminium reinforced epoxy (GLARE) is cumbersome due to distinctively different mechanical and thermal properties of its constituents, which makes it challenging to achieve damage-free holes with the acceptable surface quality. The proposed work focuses on the study of the machinability of thin (~2.5 mm) GLARE laminate. Drilling trials were conducted to analyse the effect of feed rate and spindle speed on the cutting forces and hole quality. The resulting hole quality metrics (surface roughness, hole size, circularity error, burr formation and delamination) were assessed using surface profilometry and optical scanning techniques. A three dimensional (3D) finite-element (FE) model of drilling GLARE laminate was also developed using ABAQUS/Explicit to help understand the mechanism of drilling GLARE. The homogenised ply-level response of GLARE laminate was considered in the FE model to predict cutting forces in the drilling process.

/pdf/3d-finite-element-modelling-of-cutting-forces-in-drilling-1vnpn15sce.pdf

3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

https://cyberleninka.org/article/n/495938.pdf

Vaibhav A. Phadnis

Papers

Drilling in carbon/epoxy composites: experimental investigations and finite element implementation

Effect of ultrasonically-assisted drilling on carbon-fibre-reinforced plastics

Assessment of cutting forces and hole quality in drilling Al2024 aluminium alloy: experimental and finite element study

3D Finite Element Modelling of Cutting Forces in Drilling Fibre Metal Laminates and Experimental Hole Quality Analysis

Experimental and Numerical Investigations in Conventional and Ultrasonically Assisted Drilling of CFRP Laminate