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Impact of cooled compressed air and high-speed cutting on the drilling of hybrid composite-metal stacks

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Abstract

Hybrid composite-metal stacks (HCMS) combine metal alloys and composite materials and are used in the manufacturing and maintenance of aircrafts. Drilling is an important manufacturing process necessary for installing rivets in fuselages. This work sought to identify the influence of cooled compressed air and high-speed cutting (HSC) on drilling multi-material joints with different configurations. Among the factors observed are the composite type (carbon- or glass-fiber-reinforced polymer), joint type with 2024 aluminum alloy (simple or composed), presence or absence of cooled air, cutting speed (40 and 220 m/min), and feed rate (0.02 and 0.08 mm/rev) in HCMS drilling. Adjusted delamination factor, hole-wall roughness, hole roundness, and thrust force were evaluated. The combined effect between cutting speed and cooled air did not significantly impact the defects generated, making it possible to use HSC without harming the joint. Cooled air showed a tendency to decrease defects in HCMS drilling.

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Acknowledgements

The authors thank the Sandvik Coromant for donating drills, the GEA-EESC-USP for the CFRP and GFRP plates, and the Embraer for the Al 2124 plate. The authors also thank the CIDEM-ISEP and INEGI-FEUP (Portugal) for the availability of equipment and systems, the CMM-UFRGS for valuable aid to image processing (MEV/EDS), and the Micromazza Co. for roundness error tests.

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Authors and Affiliations

  1. Laboratory of Automation in Machining (LAUS), Mechanical Engineering Department (DEMEC), Federal University of Rio Grande Do Sul (UFRGS), Porto Alegre, RS, Brazil

    Cristiano Devitte, André J. Souza & Heraldo J. Amorim

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  1. Cristiano Devitte
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Each author contributed to the research presented in this manuscript, approved the contents now presented, and agreed to the compliance with ethical standards.

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Correspondence to André J. Souza.

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Devitte, C., Souza, A.J. & Amorim, H.J. Impact of cooled compressed air and high-speed cutting on the drilling of hybrid composite-metal stacks. Int J Adv Manuf Technol 125, 5445–5461 (2023). https://doi.org/10.1007/s00170-023-11083-z

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