Tool geometry based prediction of critical thrust force while drilling carbon fiber reinforced polymers

doi:10.1007/s40436-015-0129-y

Abstract

Abstract: Carbon fiber reinforced polymers (CFRPs) are known to be difficult to cut due to the abrasive nature of carbon fibers and the low thermal conductivity of the polymer matrix. Polycrystalline diamond (PCD) drills are commonly employed in CFRP drilling to satisfy hole quality conditions with an acceptable tool life. Drill geometry is known to be influential on the hole quality and productivity of the process. Considering the variety of CFRP laminates and available PCD drills on the market, selecting the suitable drill design and process parameters for the CFRP material being machined is usually performed through trial and error. In this study, machining performances of four different PCD drills are investigated. A mechanistic model of drilling is used to reveal trade-offs in drill designs and it is shown that it can be used to select suitable feed rate for a given CFRP drilling process.

Key words: Machining, Drilling, Carbon fiber reinforced polymer (CFRP), Polycrystalline diamond (PCD), Delamination

Y. Karpat, O. Bahtiyar. Tool geometry based prediction of critical thrust force while drilling carbon fiber reinforced polymers[J]. Advances in Manufacturing, 2015, 3(4): 300-308.

TrendMD

References

1. König W, Wulf C, Graß P et al (1985) Machining of fibre reinforced plastics. CIRP Ann Manuf Technol 34(2):537-548

2. Ho-cheng H, Dharan CKH (1990) Delamination during drilling in composite laminates. J Manuf Sci Eng 112(3):236-239

3. Zhang LB, Wang LJ, Liu XY (2001) A mechanical model for predicting critical thrust forces in drilling composite laminates. Proc Inst Mech Eng Part B 215(2):135-146

4. Faraz A, Biermann D, Weinert K (2009) Cutting edge rounding: an innovative drill wear criterion in drilling CFRP composite laminates. Int J Mach Tools Manuf 49(15):1185-1196

5. Karpat Y, De?er B, Bahtiyar O (2012) Drilling thick fabric woven CFRP laminates with double point angle drills. J Mater Process Technol 212(10):2117-2127

6. Shyha IS, Aspinwall DK, Soo SL et al (2009) Drill geometry and operating effects when cutting small diameter holes in CFRP. Int J Mach Tools Manuf 49(12):1008-1014

7. Abraõ AM, Rubio JCC, Faria PE et al (2008) The effect of cutting tool geometry on thrust force and delamination when drilling glass fibre reinforced plastic composite. Mater Des 29(2):508-513

8. Duraõ LMP, Gonçalves DJS, Tavares JMRS et al (2010) Drilling tool geometry evaluation for reinforced composite laminates. Compos Struct 92(7):1545-1550

9. Karpat Y, De?er B, Bahtiyar O (2014) Experimental evaluation of polycrystalline diamond tool geometries while drilling carbon fiber-reinforced plastics. Int J Adv Manuf Technol 71(5-8):1295-1307

10. Lazar MB, Xirouchakis P (2013) Mechanical load distribution along the main cutting edges in drilling. J Mater Process Technol 213(2):245-260

11. Karpat Y, Bahtiyar O, De?er B et al (2014) A mechanistic approach to investigate drilling of UD-CFRP laminates with PCD drills. CIRP Annals-Manuf Technol 63(1):81-84

12. Meng Q, Zhang K, Cheng H et al (2015) An analytical method for predicting the fluctuation of thrust force during drilling of unidirectional carbon fiber reinforced plastics. J Compos Mater 49(6):699-711

13. Sadek A, Shi B, Meshreki M et al (2015) Prediction and control of drilling-induced damage in fibre-reinforced polymers using a new hybrid force and temperature modelling approach. CIRP Annals-Manuf Technol 64(1):89-92

14. Hocheng H, Tsao CC (2006) Effects of special drill bits on drilling-induced delamination of composite materials. Int J Mach Tools Manuf 46(12-13):1403-1416

15. Isbilir O, Ghassemieh E (2013) Numerical investigation of the effects of drill geometry on drilling induced delamination of carbon fiber reinforced composites. Compos Struct 105(8):126-133

16. Karpat Y, Bahtiyar O (2015) Comparative analysis of PCD drill designs during drilling of CFRP laminates. Proceedings of the 15th CIRP conference on modelling of machining operations, Procedia Cirp, 31:316-321

[1]	Hao Sun, Sheng-Qiang Zhao, Fang-Yu Peng, Rong Yan, Xiao-Wei Tang. Allowance distribution and parameters optimization for high-performance machining of low rigidity parts in multistage machining processes [J]. Advances in Manufacturing, 2025, 13(3): 584-605.
[2]	Lin Gu, Ke-Lin Li, Xiao-Ka Wang, Guo-Jian He. The effect of the slope angle and the magnetic field on the surface quality of nickel-based superalloys in blasting erosion arc machining [J]. Advances in Manufacturing, 2025, 13(3): 620-633.
[3]	Yi-Fan Li, Liang-Chi Zhang. Role of interatomic potentials in molecular dynamics simulations of silicon nanomachining [J]. Advances in Manufacturing, 2025, 13(2): 265-283.
[4]	Yun-Song Lian, Min Zhang, Xiao-Hui Chen, Shu-Wen Peng, Liang-Liang Lin, Chao Liu, Xu-Yang Chu, Wei Zhou. Cutting performance optimization and experimental research of indexable insert drill [J]. Advances in Manufacturing, 2025, 13(2): 303-321.
[5]	Jia-Hao Liu, Dong-Zhou Jia, Chang-He Li, Yan-Bin Zhang, Ying Fu, Zhen-Lin Lv, Shuo Feng. Mechanism and machinability in novel electroplastic-assisted grinding ductile iron [J]. Advances in Manufacturing, 2025, 13(1): 245-263.
[6]	Ming-Ming Lu, Ya-Kun Yang, Jie-Qiong Lin, Yong-Sheng Du, Xiao-Qin Zhou. Research progress of magnetorheological polishing technology: a review [J]. Advances in Manufacturing, 2024, 12(4): 642-678.
[7]	Hao-Liang Shi, Ping-Yu Jiang. Quality control in multistage machining processes based on a machining error propagation event-knowledge graph [J]. Advances in Manufacturing, 2024, 12(4): 679-697.
[8]	Xiu-Lei Yue, Zhi-Dong Liu, Shun-Cheng Zhou, Zi-Long Feng. Study of atomized discharge ablation-chemical composite machining of SiCp/Al [J]. Advances in Manufacturing, 2024, 12(4): 798-809.
[9]	Tuhin Kar, Swarup S. Deshmukh, Arjyajyoti Goswami. Fabrication of micro holes using low power fiber laser: surface morphology, modeling and soft-computing based optimization [J]. Advances in Manufacturing, 2024, 12(4): 810-831.
[10]	Qiang Gao, Ya-Ou Zhang, Xue-Cheng Xi, Yuan-Ding Wang, Xiao-Fei Chen, Wan-Sheng Zhao. Research on feed-pulse collaborative control method in micro-electrical discharge machining [J]. Advances in Manufacturing, 2024, 12(2): 270-287.
[11]	Cheng Tang, Zhao Han, Zhong-Qi Zhou, Xiao-Long Fang. Precision wire electrochemical machining of thick structures in powder superalloy René 88DT using a partially insulated tube electrode [J]. Advances in Manufacturing, 2023, 11(4): 618-635.
[12]	Jian Wang, Xue-Cheng Xi, Ya-Ou Zhang, Fu-Chun Zhao, Wan-Sheng Zhao. Stage identification and process optimization for fast drilling EDM of film cooling holes using KBSI method [J]. Advances in Manufacturing, 2023, 11(3): 477-491.
[13]	Guo-Dong Liu, Yu-Lan Zhu, Sheng-Gui Liu, Chao-Jiang Li. Research on conductive-material-filled electrodes for sidewall insulation performance in micro electrochemical machining [J]. Advances in Manufacturing, 2023, 11(3): 509-522.
[14]	Lorcan O'Toole, Feng-Zhou Fang. Optimal tool design in micro-milling of difficult-to-machine materials [J]. Advances in Manufacturing, 2023, 11(2): 222-247.
[15]	Bo-Hao Li, Li-Ping Zhao, Yi-Yong Yao. Multiconditional machining process quality prediction using deep transfer learning network [J]. Advances in Manufacturing, 2023, 11(2): 329-341.