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Mechanistic force modelling in drilling of AFRP composite considering the chisel edge extrusion

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Abstract

Aramid fiber–reinforced plastic (AFRP) composites have been widely used in automotive, aerospace, and defense industries. The common AFRP drilling process tends to cause damage to the composite structures which subsequently affects their fatigue lives and in-service performance. Understanding the mechanism of cutting force generation is crucial in controlling the cutting process for achieving desired hole quality and machining accuracy. This study proposes a novel mechanistic model considering both the cutting action and the extrusion action of the chisel edge. For the first time, the extrusion force generated by the chisel edge has been considered as a rigid wedge penetrating into an elastic half space based on the Hertz contact theory. The total thrust force in AFRP drilling is divided into three components: (i) thrust force generated by the cutting lips, (ii) thrust force generated by the chisel edge cutting action, and (iii) extrusion force generated by the chisel edge extrusion action. The proposed model was then validated by experiments and data was compared with the case where extrusion was not considered. The results show that our novel mechanistic model can provide a more accurate thrust force prediction. The average error of our model was 2.54% against the experimental data, whereas the error seen in conventional model without accounting extrusion was 8.22%. This suggests that the chisel edge extrusion plays a significant part in the drilling of AFRP and hence confirms the necessity of considering extrusion in establishing the associated mechanistic model.

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Funding

This project has received funding from the National Natural Science Foundation of China (Grant No. 51705362), the Natural Science Foundation of Tianjin (Grant No. 18JCQNJC75600), the Science & Technology Development Fund of Tianjin Education Commission for Higher Education (Grant No. 2017KJ081), and the European Union’s Horizon 2020 research and innovation program (Grant No. 734272). The authors also thank Chinese Scholarship Council for funding support (Contract No. 201808120102).

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Authors and Affiliations

  1. Tianjin Key Laboratory of Advanced Mechatronics Equipment Technology, Tianjin Polytechnic University, Tianjin, 300387, China

    Sinan Liu, Tao Yang, Chang Liu & Yifei Shen

  2. School of Mechanical Engineering, Tianjin Polytechnic University, Tianjin, 300387, China

    Sinan Liu, Tao Yang, Chang Liu & Yifei Shen

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

    Sinan Liu, Chang Liu, Yan Jin & Dan Sun

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  1. Sinan Liu
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  2. Tao Yang
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  3. Chang Liu
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  4. Yan Jin
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  5. Dan Sun
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  6. Yifei Shen
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Correspondence to Tao Yang.

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Liu, S., Yang, T., Liu, C. et al. Mechanistic force modelling in drilling of AFRP composite considering the chisel edge extrusion. Int J Adv Manuf Technol 109, 33–44 (2020). https://doi.org/10.1007/s00170-020-05608-z

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  • DOI: https://doi.org/10.1007/s00170-020-05608-z

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