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Study of delamination in drilling carbon fiber reinforced plastics (CFRP) using design experiments.pdf

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Study of delamination in drilling carbon fiber reinforced plastics (CFRP) using design experiments.pdf

STUDYOFDELAMINATIONINDRILLINGCARBONfiBERREINFORCEDPLASTICSCFRPUSINGDESIGNEXPERIMENTSJPDAVIM,PEDROREISDEPARTMENTOFMECHANICALENGINEERING,UNIVERSITYOFAVEIROCAMPUSSANTIAGO,3810193AVEIRO,PORTUGALABSTRACTINTHISPAPERISPRESENTEDANEWCOMPREHENSIVEAPPROACHTOSELECTCUTTINGPARAMETERSFORDAMAGEFREEDRILLINGINCARBONfiBERREINFORCEDEPOXYCOMPOSITEMATERIALTHEAPPROACHISBASEDONACOMBINATIONOFTAGUCHIC213STECHNIQUESANDONTHEANALYSISOFVARIANCEANOVAAPLANOFEXPERIMENTS,BASEDONTHETECHNIQUESOFTAGUCHI,WASPERFORMEDDRILLINGWITHCUTTINGPARAMETERSPREfiXEDINANAUTOCLAVECARBONfiBERREINFORCEDPLASTICCFRPLAMINATETHEANOVAISEMPLOYEDTOINVESTIGATETHECUTTINGCHARACTERISTICSOFCFRPC213SUSINGHIGHSPEEDSTEELHSSANDCEMENTEDCARBIDEK10DRILLSTHEOBJECTIVEWASTOESTABLISHACORRELATIONBETWEENCUTTINGVELOCITYANDFEEDRATEWITHTHEDELAMINATIONINACFRPLAMINATETHECORRELATIONWASOBTAINEDBYMULTIPLELINEARREGRESSIONFINALLY,CONfiRMATIONTESTSWEREPERFORMEDTOMAKEACOMPARISONBETWEENTHERESULTSFORESEENFROMTHEMENTIONEDCORRELATIONC2112002ELSEVIERSCIENCELTDALLRIGHTSRESERVEDKEYWORDSDRILLING;CARBONfiBERREINFORCEDPLASTICS;DELAMINATIONFACTOR;TAGUCHIC213STECHNIQUES;ANALYSISOFVARIANCE1INTRODUCTIONOWINGTOTHEGROWINGUSEOFCOMPOSITEMATERIALS,SPECIfiCALLYTHEfiBERREINFORCEDPLASTICSFRPOUTSIDETHEDEFENCEINDUSTRYANDTHEAEROSPACEINDUSTRY,THEUNITCOSTREPLACESTHEPERFORMANCEATANYCOSTASTHEMAINCONCERNFORPRODUCTIONSO,THEPRODUCTIONTECHNOLOGIES,ESPECIALLYTHEMACHININGOFCOMPOSITES,AREASSUMINGAMOREANDMORESIGNIfiCANTROLEASTHEYCONDITIONTHEECONOMICVIABILITYOFTHEPRODUCTMACHININGCOMPOSITEMATERIALSISARATHERCOMPLEXTASKOWINGTOITSHETEROGENEITY,HEATSENSITIVITY,ANDTOTHEFACTTHATREINFORCEMENTSAREEXTREMELYABRASIVECONVENTIONALMACHININGMETHODSSHOULDBEADAPTEDINSUCHAWAYTHATTHEYDIMINISHTHERMALANDMECHANICALDAMAGEDRILLINGISAFREQUENTLYPRACTICEDMACHININGPROCESSININDUSTRYOWINGTOTHENEEDFORCOMPONENTASSEMBLYINMECHANICALPIECESANDSTRUCTURESTHEDRILLINGOFLAMINATECOMPOSITEMATERIALSISSIGNIfiCANTLYAffECTEDBYTHETENDENCYOFTHESEMATERIALSTODELAMINATEANDTHEfiBERSTOBONDFROMTHEMATRIXUNDERTHEACTIONOFMACHININGFORCESTHRUSTFORCEANDTORQUEMANYAUTHORS1–3,WHENREPORTINGABOUTTHEDRILLINGOFLAMINATEDCOMPOSITEMATERIALSBYCONVENTIONALTOOLS,HAVESHOWNTHATTHEQUALITYOFTHECUTSURFACESISSTRONGLYDEPENDENTONTHEDRILLINGPARAMETERS,TOOLGEOMETRYANDTOOLMATERIALANINAPPROPRIATECHOICEOFTHESEPARAMETERSCANLEADTOUNACCEPTABLEMATERIALDEGRADATION,SUCHASfiBERPULLOUT,MATRIXCRATERING,THERMALDAMAGEANDDELAMINATIONAMONGTHEDEFECTSCAUSEDBYDRILLING,DELAMINATIONAPPEARSTOBETHEMOSTCRITICALLAMINATEDfiBERREINFORCEDPLYC213SUNDERMACHININGFORCESARESUBJECTTOTHERISKOFINTERLAMINARCRACKPROPAGATION,CALLEDDELAMINATIONKOENIGETAL,STUDIEDIN1985THEMACHININGOFfiBERREINFORCEDPLASTICSANDCONCLUDEDTHATAHIGHFEEDRATEOFDRILLINGWILLCAUSEACRACKAROUNDTHEEXITEDGEOFTHEHOLE4MILLERPRESENTEDIN1987ADATABASEONOPTIMUMCUTTINGPARAMETERSFORDRILLINGHOLESWITHMINIMUMLOCALMACHININGDAMAGE5HOCHENGANDPUW1,IN1992PRESENTEDASTUDYOFTHECHIPFORMATIONANDASSESSESTHEMACHINABILITYOFTWOCOMPOSITEMATERIALSTHERMOSETBASEDANDTHERMOPLASTICSBASEDANDCONCLUDEDTHATFROMCUTTINGCHIPSTHEFORMERPRESENTSALARGEAMOUNTOFDEFORMATIONINCHIPFORMATION,WHILETHELATTERTENDSTOFRACTUREHECORRESPONDINGAUTHORFAX351234370953EMAILADDRESSPDAVIMMECUAPTJPDAVIM02638223/03/SEEFRONTMATTERC2112002ELSEVIERSCIENCELTDALLRIGHTSRESERVEDPIIS026382230200257XCOMPOSITESTRUCTURES592003481–487WWWELSEVIERCOM/LOCATE/COMPSTRUCTALSONOTICEDTHATCARBON/ABSISSUPERIORTOCARBON/EPOXYFORSURFACEQUALITYANDBOTHHOLEEDGESCHAMBERSANDBISHOP6IN1995INVESTIGATEDTHEEffECTOFTHECUTTINGPARAMETERSONDRILLINGCARBON/EPOXYANDCARBON/PEEKANDCONCLUDEDTHATTHEDRILLINGOFCARBONCOMPOSITESISDEPENDENTUPONTHECHARACTERISTICSOFTHEMATRIXANDTHEHELICALPCDDRILLGEOMETRYGAVETHEBESTOVERALLPERFORMANCEINADDITIONTOTHEPROBLEMSOFTOOLWEAR,ITISVERYDIffiCULTTOACHIEVETHEQUALITYOFSURFACENEEDEDFORTHEACCURATEASSEMBLYOFCOMPONENTSINMECHANICALSTRUCTURESLINETAL7IN1996,CARRIEDOUTASTUDYONDRILLINGOFCARBONfiBERREINFORCEDCOMPOSITEATHIGHSPEEDANDCONCLUDEDTHATANINCREASEOFTHECUTTINGVELOCITYLEADSAINCREASINGOFTHEDRILLWEARINTHISWAYTHEFACTOFINCREASINGTHEWEAROFDRILLCAUSESARISINGOFTHRUSTFORCEWENCHOUCHEN3IN1997STUDIEDTHEVARIATIONSOFCUTTINGFORCESWITHORWITHOUTONSETDELAMINATIONDURINGTHEDRILLINGOPERATIONSANDCONCLUDEDTHATTHEDELAMINATIONFREEDRILLINGPROCESSESMAYBEOBTAINEDBYTHEPROPERSELECTIONSOFTOOLGEOMETRYANDDRILLINGPARAMETERSPIQUETETAL8IN2000CARRIEDOUTASTUDYOFDRILLINGTHINCARBON/EPOXYLAMINATESWITHTWOTYPESOFDRILLS,AHELICALDRILLANDADRILLOFSPECIALGEOMETRY,ANDCONCLUDEDTHATBOTHDRILLSLEADSADAMAGEATTHEENTRANCEINTHEWALLANDTHEEXITOFTHEHOLE,WITHTHEEXCEPTIONOFSPECIALGEOMETRYDRILLWHICHISPOSSIBLEASIGNIfiCANTREDUCTIONINTHEfiNALDAMAGEENEMUOHETAL9IN2001,REALIZETHATWITHTHEAPPLICATIONOFTHETECHNIQUEOFTAGUCHIANDOTHERMETHODS,WEREPOSSIBLETOACHIEVETHECUTTINGPARAMETERSTHATALLOWEDTHEABSENCEOFDAMAGEINTHEDRILLINGOFfiBERREINFORCEDPLASTICSALLTHEABOVEWORKSCONTRIBUTESTOTHEPRACTICEOFCUTTINGCOMPOSITEMATERIALS,BUTTHEYDONOTSHOWTHEBASICMECHANISMSOFCUTANDTHECHARACTERIZATIONOFTHEMACHINABILITY2EXPERIMENTALPROCEDURE21MEANSANDMATERIALSINORDERTOACHIEVETHEOBJECTIVEOFTHISEXPERIMENTALWORK,MAINLYTHEESTABLISHINGOFCORRELATIONSBETWEENTHECUTTINGCONDITIONSWITHTHED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