Drilling Strategy for Thick Carbon Fiber Reinforced Polymer Composites (CFRP): A Preliminary Assessment
Keywords:delamination, drilling, heat-affected zone (HAZ), laser machining, thick carbon fiber reinforced polymer composites (CFRP).
AbstractCarbon fiber reinforced polymer or CFRP composites are the epitome of high-performance materials in lightweight design. However, their machinability can be problematic due to non-homogenous and anisotropic material properties. This preliminary assessment emphasizes drilling strategy by using mechanical drilling and laser machining on 25.4 mm thick CFRP, which has not been investigated so far. In mechanical drilling, three drilling strategies were applied with the same parameters in order to assess the feasibility of drilling thick CFRP. The laser machining experiments were conducted to identify the potential of fiber laser machines to cut thick CFRP due to their superior laser beam quality. The results showed that choosing the appropriate drilling strategy in mechanical drilling is essential for reducing damage when drilling thick CFRP. Significant damage occurred in all experiments. The results are useful to define the relationships between machining parameters related to mechanical/laser drilling and hole/cut quality.
Kalpakjian, S. & Schmid, S.R., Manufacturing Engineering and Technology (International Edition), Pearson Publishing, Fourth Edition, 1999.
Pecat, O., Rentsch, R. & Brinksmeier, E., Influence of Milling Process Parameters on the Surface Integrity of CFRP, Procedia CIRP, 1, pp. 466-470, 2012.
Hintze, W., Hartmann, D. & Schutte, C., Occurrence and Propagation of Delamination during the Machining of Carbon Fibre Reinforced Plastics (CFRPs)-An Experimental Stud,. Composites Science and Technology, 71, pp. 1719-1726, 2011.
Komanduri, R., Machining Fiber-reinforced Composites, Mechanical Engineering (ISSN 0025-6501), 115(4): pp. 58-64, 1997.
Sheikh-Ahmad, J.Y., Machining of Polymer Composites, New York: Springer, 2009.
Liu, D.F, Tang, Y.J. & Gong, W.L., A Review of Mechanical Drilling for Composite Material, Composite Structures, 94(2012) pp.1265-1279
Li, L., Low, D.K.Y., Ghoreshi, M. & Crookall, J.R., Hole Taper Characterisation and Control in Laser Percussion Drilling, CIRP Annals-Manufacturing Technology, 51 (1), pp.153 156, 2002.
Li, Z.L., Zheng, H.Y., Lim, G.C., Chu, P. L., Li, L., Marimuthu, S., Negarestani, R., Sheikh, M. & Mativenga, P., Process Development of Laser Machining of Carbon Fibre Reinforced Plastic Composites, in International Congress on Applications of Lasers and Elctro-Optics, ICALEO, Temecula, CA, USA, 2008.
Shanmugam, D.K., Chen, F.L., Siores, E. & Brandt, M., Comparative Study of Jetting Machining Technologies over Laser Machining Technology for Cutting Composite Materials, Composite Structures, 57(1-4), pp. 289-296, 2002.
Abrate, S. & Walton, D.A., Machining of Composite Materials. Part II: Non-traditional Methods, Composites Manufacturing, 3(2), pp. 85-94, 1992.
Steen, W.M. & Mazumder, J., Laser Material Processing, Springer, 2010.
Reza, N. & Li, L., Fibre Laser Cutting of Carbon Fibre-reinforced Polymeric Composites, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 0954405413490513, 2013.
Hernandez-Castaneda, J.C., Sezer, H.K. & Li, L., The Effect of Moisture Content in Fibre Laser Cutting of Pine Wood, Optics and Lasers in Engineering, 49, pp. 1139-1152, 2011.
Davim, J.P., Rubio, J.C. & Abrao, A.M., A Novel Approach based on Digital Image Analysis to Evaluate the delamination Factor after Drilling Composite Laminates, Compos Sci Technol, 67, pp. 1939-1945, 2007.
Sandvik Coromant, Machining Carbon Fibre Materials, http://www.sandvik.coromant.com/sitecollectiondocuments/downloads/global/technical%20guides/en-gb/c-2920-30.pdf, 2015. (Accessed 06 October 2015)
Shyha, I.S., Soo, S.L., Aspinwall, D. & Bradley, S., Effect of Laminate Configuration and Feed Rate on Cutting Performance when Drilling Holes in Carbon Fibre Reinforced Plastic Composites, Journal of Materials Processing Technology, 210 (8), pp. 1023-1034, 2010.
Khan, Z.M., A Study of the Drilling of Advanced Carbon Fibre Composites, PhD Thesis, the University of Salford, United Kingdom, 1991.