Skip to main content
SpringerLink
Log in

Performance and mechanism of hole-making of CFRP/Ti-6Al-4V stacks using ultrasonic vibration helical milling process

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

This work firstly evaluated the machinability of ultrasonic vibration helical milling (UVHM) process on the multilayer carbon fiber reinforced polymer (CFRP)/Ti-6Al-4V stacks, comparing with conventional helical milling (HM). Cutting force, hole edge quality, hole surface morphologies, hole dimensional accuracy, and tool wear were presented to analyze the effect of UVHM on the hole-making performance of stacks structures. The axial forces in machining of CFRP phase and Ti-6Al-4V alloy in UVHM were 2.62–19.92% and 0.95–8.44% less than those in HM, respectively. The hole edge quality and hole surface morphologies of CFRP phase in stacks was improved in UVHM, which is caused by the periodic shear effect between the cutting edge and fibers due to the ultrasonic vibration. The delamination damages of CFRP phase in UVHM were slightly improved compared with that in HM. The delamination factor in UVHM was slightly less than that in HM. The hole diameter error decreased with the increasing number of holes in both HM and UVHM, and the diameter error in UVHM was larger than that in HM. Due to the existence of interface in the stacks structure, the diameter of CFRP phase increase and the diameter of Ti-6Al-4V alloy decrease with the increase of axial depth. The average flank wear of the bottom cutting edge in UVHM was 2.14–19.28% less than that in HM. The main wear mode in HM and UVHM was adhesive wear, diffusion wear, and oxidation wear. However, the adhesive wear was alleviated due to the micro-impact effect and friction behavior caused by the separated cutting characteristic in UVHM. These improvements of hole quality indicated that UVHM is feasible in improving hole quality and tool life for hole-making of multilayer stacks.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25

Similar content being viewed by others

Data availability

The data presented and/or analyzed during the current study are available from the corresponding author on reasonable request.

Abbreviations

A :

The vibration amplitude (mm)

a p :

The axial feed per orbital revolution (mm/r)

D h :

The target diameter of machined hole (mm)

D t :

The diameter of cutting tool (mm)

D o :

The nominal hole diameter (mm)

Dmax :

The maximum delaminated diameter of damage area (mm)

e :

The radius of orbital revolution (mm)

F c :

The resultant force calculated by measured force along X and Y direction (N)

F d :

The one-dimension delamination factor

F x :

The measured force along X direction (N)

F y :

The measured force along Y direction (N)

F z :

The measured force along Z direction (N)

f :

The vibration frequency (Hz)

f a :

The axial feed speed (mm/min)

f zt :

The tangential feed per tooth (mm/r)

n rev :

The orbital revolution speed (rpm)

n rot :

The spindle rotation speed (rpm)

r :

The length of bottom cutting edge (mm)

s :

The length along the tangential direction of the trajectory (mm)

t :

The cutting time (s)

v 1 :

The orbital speed of the tool center (mm/s)

v 2 :

The self-rotation speed of cutting tool (mm/s)

v s :

The speed of peripheral cutting edge along the trajectory direction (mm/s)

v t :

The resultant cutting speed of a bottom trajectory (mm/s)

v z :

The speed of peripheral cutting edge along the axial direction (mm/s)

v T-h :

The speed of peripheral cutting edge along the cutting-edge direction (mm/s)

v T-t :

The speed of peripheral cutting edge normal to the cutting-edge direction (mm/s)

Z :

The displacement along the axial direction of tool (mm)

Ze :

The number of tool edges

δ :

The helical angle of peripheral cutting edge (°)

(θ 1, θ 2, θ 3):

The relevant angles used for calculating the speeds vt (°)

φ :

The intersection angle between the two cutting speeds (°)

ω 1 :

The angle speed of orbital revolution (rad/s)

ω 2 :

The angle speed of spindle rotation (rad/s)

References

  1. Xu J, El Mansori M (2016) Experimental studies on the cutting characteristics of hybrid CFRP/Ti stacks. Proc Manuf 5:270–281

    Google Scholar 

  2. Wang CY, Chen YH, An QL, Cai XJ, Ming WW, Chen M (2015) Drilling temperature and hole quality in drilling of CFRP/aluminum stacks using diamond coated drill. Int J Precis Eng Manuf 16(8):1689–1697

    Article  Google Scholar 

  3. Zitoune R, Krishnaraj V, Collombet F, Le Roux S (2016) Experimental and numerical analysis on drilling of carbon fibre reinforced plastic and aluminium stacks. Compos Struct 146:148–158

    Article  Google Scholar 

  4. Zhou L, Ke Y, Dong H, Chen Z, Gao K (2016) Hole diameter variation and roundness in dry orbital drilling of CFRP/Ti stacks. Int J Adv Manuf Technol 87:811–824

    Article  Google Scholar 

  5. Zitoune R, Krishnaraj V, Collombet F (2010) Study of drilling of composite material and aluminium stack. Compos Struct 92:1246–1255

    Article  Google Scholar 

  6. Ramulu M, Branson T, Kim D (2001) A study on the drilling of composite and titanium stacks. Compos Struct 54:67–77

    Article  Google Scholar 

  7. Cong WL, Pei ZJ, Deines TW, Liu DF, Treadwell C (2013) Rotary ultrasonic machining of CFRP/Ti stacks using variable feedrate. Compos Part B 52:303–310

    Article  Google Scholar 

  8. Zitoune R, Krishnaraj V, Sofiane Almabouacif B, Collombet F, Sima M, Jolin A (2012) Influence of machining parameters and new nano-coated tool on drilling performance of CFRP/aluminium sandwich. Compos Part B 43:1480–1488

    Article  Google Scholar 

  9. Xu J, Li C, Chen M, Ren F (2019) A comparison between vibration assisted and conventional drilling of CFRP/Ti6Al4V stacks. Mater Manuf Process 34(10):1182–1193

    Article  Google Scholar 

  10. Kuo CL, Soo SL, Aspinwall DK, Bradley S, Thomas W, M’Saoubi R, Pearson D, Leahy W (2014) Tool wear and hole quality when single-shot drilling of metallic-composite stacks with diamond-coated tools. Proc Inst Mech Eng B J Eng Manuf 228:1314–1322

    Article  Google Scholar 

  11. Davim JP, Reis P (2003) Drilling carbon fiber reinforced plastics manufactured by autoclave—experimental and statistical study. Mater Des 24:315–324

    Article  Google Scholar 

  12. Shyha I, Soo SL, Aspinwall DK, Bradley S, Dawson S, Pretorius CJ (2010) Drilling of titanium/CFRP/aluminium stacks. Key Eng Mater 447-448:624–633

    Article  Google Scholar 

  13. Shyha I, Soo SL, Aspinwall DK, Bradley S, Perry R, Harden P, Dawson S (2011) Hole quality assessment following drilling of metallic-composite stacks. Int J Mach Tools Manuf 51:569–578

    Article  Google Scholar 

  14. Alonso U, Calamaz M, Girot F, Iriondo E (2019) Influence of flute number and stepped bit geometry when drilling CFRP/Ti6Al4V stacks. J Manuf Process 39:356–370

    Article  Google Scholar 

  15. Li S, Qin X, Jin Y, Sun D, Li Y (2017) A comparative study of hole-making performance by coated and uncoated WC/Co cutters in helical milling of Ti/CFRP stacks. Int J Adv Manuf Technol 94:2645–2658

    Article  Google Scholar 

  16. Pramanik A, Littlefair G (2014) Developments in machining of stacked materials made of CFRP and titanium/aluminum alloys. Mach Sci Technol 18:485–508

    Article  Google Scholar 

  17. Li H, He G, Qin X, Wang G, Lu C, Gui L (2014) Tool wear and hole quality investigation in dry helical milling of Ti-6Al-4V alloy. Int J Adv Manuf Technol 71:1511–1523

    Article  Google Scholar 

  18. Liu J, Chen G, Ji C, Qin X, Li H, Ren CZ (2014) An investigation of workpiece temperature variation of helical milling for carbon fiber reinforced plastics (CFRP). Int J Mach Tools Manuf 86:89–103

    Article  Google Scholar 

  19. Ning F, Wang H, Cong W, Fernando P (2017) A mechanistic ultrasonic vibration amplitude model during rotary ultrasonic machining of CFRP composites. Ultrasonics 76:44–51

    Article  Google Scholar 

  20. Geng D, Liu Y, Shao Z, Lu Z, Cai J, Li X, Jiang XG, Zhang DY (2019) Delamination formation, evaluation and suppression during drilling of composite laminates: a review. Compos Struct 216:168–186

    Article  Google Scholar 

  21. Wang B, Gao H, Cao B, Zhuang Y, Zhao Z (2014) Mechanism of damage generation during drilling of carbon/epoxy composites and titanium alloy stacks. Proc Inst Mech Eng B J Eng Manuf 228:698–706

    Article  Google Scholar 

  22. Denkena B, Boehnke D, Dege J (2008) Helical milling of CFRP–titanium layer compounds. CIRP J Manuf Sci Technol 1:64–69

    Article  Google Scholar 

  23. Wang G-D, Melly SK, Li N, Peng T, Li Y (2018) Research on milling strategies to reduce delamination damage during machining of holes in CFRP/Ti stack. Compos Struct 200:679–688

    Article  Google Scholar 

  24. Wang H, Qin X, Li H, Tan Y (2016) A comparative study on helical milling of CFRP/Ti stacks and its individual layers. Int J Adv Manuf Technol 86:1973–1983

    Article  Google Scholar 

  25. Sanda A, Arriola I, Garcia Navas V, Bengoetxea I, Gonzalo O (2016) Ultrasonically assisted drilling of carbon fibre reinforced plastics and Ti6Al4V. J Manuf Process 22:169–176

    Article  Google Scholar 

  26. Li C, Xu J, Chen M, An Q, El Mansori M, Ren F (2019) Tool wear processes in low frequency vibration assisted drilling of CFRP/Ti6Al4V stacks with forced air-cooling. Wear 426-427:1616–1623

    Article  Google Scholar 

  27. Dong S, Liao W, Zheng K, Liu J, Feng J (2019) Investigation on exit burr in robotic rotary ultrasonic drilling of CFRP/aluminum stacks. Int J Mech Sci 151:868–876

    Article  Google Scholar 

  28. Dahnel AN, Ascroft H, Barnes S, Gloger M (2016) Analysis of tool wear and hole quality during ultrasonic assisted drilling (UAD) of carbon fibre composite (CFC) / titanium alloy (Ti6Al4V) stacks. Proc CIRP 46(1):420–423

    Article  Google Scholar 

  29. Onawumi PY, Roy A, Silberschmidt VV, Merson E (2018) Ultrasonically assisted drilling of aerospace CFRP/Ti stacks. Proc CIRP 77:383–386

    Article  Google Scholar 

  30. Ishida T, Noma K, Kakinuma Y, Aoyama T, Hamada S, Ogawa H, Higaino T (2014) Helical milling of carbon fiber reinforced plastics using ultrasonic vibration and liquid nitrogen. Proc CIRP 24:13–18

    Article  Google Scholar 

  31. Zou Y, Chen G, Lu L, Qin X, Ren C (2019) Kinematic view of cutting mechanism in hole-making process of longitude-torsional ultrasonic assisted helical milling. Int J Adv Manuf Technol 103:267–280

    Article  Google Scholar 

  32. Geng D, Teng Y, Liu Y, Shao Z, Jiang X, Zhang D (2019) Experimental study on drilling load and hole quality during rotary ultrasonic helical machining of small-diameter CFRP holes. J Mater Process Technol 270:195–205

    Article  Google Scholar 

  33. Chen G, Ren C, Zou Y, Qin X, Lu L, Li S (2019) Mechanism for material removal in ultrasonic vibration helical milling of Ti6Al4V alloy. Int J Mach Tools Manuf 138:1–13

    Article  Google Scholar 

  34. Xu J, El Mansori M (2016) Experimental study on drilling mechanisms and strategies of hybrid CFRP/Ti stacks. Compos Struct 157:461–482

    Article  Google Scholar 

  35. Chen G, Ren C, Lu L, Ke Z, Qin X, Ge X (2018) Determination of ductile damage behaviors of high strain rate compression deformation for Ti-6Al-4V alloy using experimental numerical combined approach. Eng Fract Mech 200:499–520

    Article  Google Scholar 

  36. Liu J, Chen G, Ren C, Qin X, Zou Y, Ge J (2020) Effects of axial and longitudinal-torsional vibration on fiber removal in ultrasonic vibration helical milling of CFRP composites. J Manuf Process 58:868–883

    Article  Google Scholar 

  37. Wang H, Qin X, Li H, Ren C (2013) Analysis of cutting force in helical milling of carbon fiber–reinforced plastics. Proc Inst Mech Eng B J Eng Manuf 227(1):62–74

    Article  Google Scholar 

  38. Bahi S, Nouari M, Moufki A, Mansori ME, Molinari A (2012) Hybrid modelling of sliding–sticking zones at the tool–chip interface under dry machining and tool wear analysis. Wear 286-287:45–54

    Article  Google Scholar 

  39. Kim D, Sturtevant C, Ramulu M (2013) Usage of PCD tool in drilling of titanium/graphite hybrid composite laminate. Int J Mach Mach Mater 13:276–288

    Google Scholar 

  40. Wang C, Liu G, An Q, Chen M (2007) Occurrence and formation mechanism of surface cavity defects during orthogonal milling of CFRP laminates. Comp Part B Eng 109:10–22

    Article  Google Scholar 

  41. Voss R, Seeholzer L, Kuster F, Wegener K (2017) Influence of fibre orientation, tool geometry and process parameters on surface quality in milling of CFRP. CIRP J Manuf Sci Technol 18:75–91

    Article  Google Scholar 

  42. Xu J, Zhou L, Chen M, Ren F (2019) Experimental study on mechanical drilling of carbon/epoxy composite-Ti6Al4V stacks. Mater Manuf Process 34:715–725

    Article  Google Scholar 

  43. Chen W-C (1997) Some experimental investigations in the drilling of carbon fiber-reinforced plastic (CFRP) composite laminates. Int J Mach Tools Manuf 37:1097–1108

    Article  Google Scholar 

  44. Chen G, Zou Y, Qin X, Liu J, Feng Q, Ren CZ (2020) Geometrical texture and surface integrity in helical milling and ultrasonic vibration helical milling of Ti-6Al-4V alloy. J Mater Process Technol 278:116494

    Article  Google Scholar 

  45. Khanna N, Agrawal C, Gupta MK, Song Q (2020) Tool wear and hole quality evaluation in cryogenic Drilling of Inconel 718 superalloy. Tribol Int 143:106084

    Article  Google Scholar 

Download references

Funding

This work was supported by the National Key Research and Development Program (No. 2017YFE0111300) and the Natural Science Foundation of China (No. 51575384).

Author information

Authors and Affiliations

  1. Key Laboratory of Mechanism Theory and Equipment Design of Ministry of Education, Tianjin University, Tianjin, 300350, China

    Yuhe Zou, Guang Chen, Chengzu Ren, Jiaying Ge & Xuda Qin

  2. Tianjin Key Laboratory of Equipment Design and Manufacturing Technology, Tianjin University, Tianjin, 300350, China

    Guang Chen, Chengzu Ren & Xuda Qin

Authors
  1. Yuhe Zou
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Guang Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Chengzu Ren
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jiaying Ge
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Xuda Qin
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Conceptualization, Guang Chen; data curation, Yunhe Zou and Jiaying Ge; formal analysis, Guang Chen, Yunhe Zou, and Chengzu Ren; funding acquisition, Guang Chen and Xuda Qin; investigation, Guang Chen, Yunhe Zou, and Jiaying Ge; methodology, Guang Chen, Yunhe Zou, and Jiaying Ge; supervision, Guang Chen, Chengzu Ren, and Xuda Qin; writing (original draft preparation), Guang Chen, Yunhe Zou, and Jiaying Ge; writing (review and editing), Chengzu Ren and Xuda Qin

Corresponding author

Correspondence to Guang Chen.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

Not applicable.

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zou, Y., Chen, G., Ren, C. et al. Performance and mechanism of hole-making of CFRP/Ti-6Al-4V stacks using ultrasonic vibration helical milling process. Int J Adv Manuf Technol 117, 3529–3547 (2021). https://doi.org/10.1007/s00170-021-07906-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07906-6

Keywords

Search

Navigation