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A mechanistic prediction model for thrust force and torque during drilling of CFRP/Ti stacks

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Abstract

Drilling holes on carbon fiber reinforced plastic/polymer (CFRP) and Ti stack structures is significantly important assembling process in aerospace manufacturing. However, it is quite a challenge that the excessive and completely different drilling loads of two materials with distinguish physical and mechanical properties will lead to frequent CFRP drilling damages and Ti burrs, as well as rapid tool failures. Therefore, understanding and controlling the drilling loads are crucial to ensure low damage and high efficiency drilling of CFRP and Ti stacks. In this paper, a novel mechanistic model was established to predict the thrust force and the torque in the drilling of CFRP and Ti stacks. The cutting loads of a twist drill were discretized along chisel edge, primary cutting edge, and minor cutting edge. An orthogonal cutting model and an oblique cutting model were proposed to represent the discretized cutting load for CFRP and Ti with the consideration of fiber cutting angles, flank face friction, and drilling parameters. Integrating the discretized cutting load, a mechanistic model for predicting thrust force and torque was developed for drilling of CFRP/Ti stack. After the coefficient calibrations, verification experiments showed that the developed model has accurately predicted the thrust force and torque under various spindle speeds/feed rates as well as the changing fiber cutting angles.

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Abbreviations

P :

Point angle

ψ :

Chisel angle

α n,lip :

Normal rake angle of cutting lip

γ :

Relief angle

α n,minor :

Normal rake angle of minor cutting edge

i :

Inclination angel

γ n, ch :

Normal relief angle of chisel edge

R :

Drill radius

R c :

Radius of the chisel edge

R m :

Length of the helix

μm :

Cutting angle of metal

ρ :

Tool rotation angle

E1, E2 :

Euler transformation matrix

A u :

Uncut area

K c :

Cutting coefficient

K p :

Contact coefficient

F xn1 , F yn1 , F zn1 :

Normal cutting force at rake face

F xf1 , F yf1 , F zf1 :

Friction force at rake face

S :

Cutting speed

2 ω :

Web thickness

α :

Rake angle

α n,ch :

Normal rake angle of chisel edge

γ n,lip :

Normal relief angle of cutting lip

γ n,minor :

Normal relief angle of minor cutting edge

μ :

Cutting angle

R :

Drill diameter

R e :

Cutting edge radius

R l :

Radius of the cutting edge

ζ :

Helix angel

μc,:

Cutting angle of CFRP

Tlip, Tmlip, Tch :

Transformation matrix

A c :

Relief contact area

K f :

Friction coefficient

Fx, Fy, Fz :

The cutting force on the drill

Fxn2, Fyn2, Fzn2 :

Normal cutting force at flank face

F xf2 , F yf2 , F zf2 :

Friction force at flank face

t :

Cutting time

f :

feed rate

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Funding

This work is supported by National Natural Science Foundation of China-United with Liaoning Province, No.U1508207, National Natural Science Foundation of China, No.51575082.

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Authors and Affiliations

  1. Key Laboratory for Precision and Non-traditional Machining Technology of the Ministry of Education, School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    Zhen-yuan Jia, Chong Zhang & Fu-ji Wang

  2. School of Mechanical and Aerospace Engineering, Queen’s University Belfast, Belfast, BT9 5AG, UK

    Rao Fu

Authors
  1. Zhen-yuan Jia
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  2. Chong Zhang
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  3. Fu-ji Wang
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  4. Rao Fu
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Correspondence to Fu-ji Wang.

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Jia, Zy., Zhang, C., Wang, Fj. et al. A mechanistic prediction model for thrust force and torque during drilling of CFRP/Ti stacks. Int J Adv Manuf Technol 106, 3105–3115 (2020). https://doi.org/10.1007/s00170-019-04861-1

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  • DOI: https://doi.org/10.1007/s00170-019-04861-1

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