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Elimination of delamination and burr formation using high-frequency vibration-assisted drilling of hybrid CFRP/Ti6Al4V stacked material

  • R. HusseinEmail author
  • A. Sadek
  • M. A. ElbestawiEmail author
  • M. H. Attia
ORIGINAL ARTICLE
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Abstract

The superior physical and mechanical characteristics of CFRP/Ti6Al4V stacked structures explain their widespread use in the aerospace industry. However, the unacceptable machining-induced tensile surface residual stresses and reduced surface integrity are the main challenges that are faced in the conventional drilling process. These types of damage are attributed to the relatively high thermal load and poor chip evacuation mechanism. Vibration-assisted drilling is a promising technique to control the uncut chip thickness, and consequently reducing the cutting energy. Moreover, the axial tool oscillation provides a mechanism for effective chip evacuation. This study presents an experimental investigation relating the high-frequency vibration-assisted drilling (HF-VAD) machining parameters to the Ti6Al4V burr formation and induced residual stresses, as well as CFRP delamination during the drilling of CFRP/Ti6Al4V staked material. Additionally, this study presents an assessment and comparison between HF-VAD and LF-VAD of CFRP/Ti6Al4V hybrid structure. The results showed up to approximately 26%, 37%, and 86% reduction in the thrust force, cutting temperature, and the exit burr height, respectively. The effect of HF-VAD on surface integrity and Ti6Al4V residual stresses are also presented. The drilling process of HF-VAD resulted in free exit delamination of CFRP with compressive residual stress on the Ti6Al4V machined surface.

Keywords

High-frequency vibration-assisted drill Machining CFRP Ti6Al4V Stacked material Surface integrity Residual stresses Delamination free Burr formation 

Acronyms

VAD

Vibration-assisted drilling

LF-VAD

Low-frequency vibration-assisted drilling

CD

Conventional drilling

HF-VAD

High-frequency vibration-assisted drilling

CFRP

Carbon fiber–reinforced polymers

RS

Residual stress

Notations

N

Rotation speed [rpm]

f

Feed rate [mm/rev]

Am

Modulation amplitude [μm]

F

Frequency [Hz]

Wf

Modulation frequency [cycle/rev]

Ød

Delamination factor [%]

E

Axial cutting edge position [mm]

Notes

Acknowledgments

The experimental investigation was performed using the National Research Council Canada, Aerospace Manufacturing Technologies Centre (AMTC) facilities. The assistance of AMTC Advanced Material removal Technology Group is greatly appreciated.

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringMcMaster UniversityHamiltonCanada
  2. 2.Aerospace ManufacturingNational Research Council CanadaQCCanada

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