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Investigation of self-adaptive drilling of CFRP/Al stacks based on equivalent impedance recognition of the vibration-assisted device

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Abstract

CFRP/Al stacks have shown a wide range of applications in the aviation industries. Component assembly requires an enormous number of holes to be drilled. In consideration of the quality and efficiency of the drilling process, it is preferred to change process parameters in real-time according to the different material properties of each ply, namely varying-parameter control. Since variable thickness designs are quite common in aviation structures, the interface of the stack is hard to define before the drilling process, which poses a challenge to interface recognition and parameter modification methods. Accordingly, a state-of-art self-adaptive drilling method based on the analysis of the equivalent impedance of a longitudinal-torsional–vibration-assisted drilling device is described in the paper. The research was carried out to implement online recognition of stack interface without using any sensors, as well as the following modification of process parameters. First, the equivalent impedance model was established by analyzing the characteristic signal of the piezoelectric transducer changing with the dynamic load. The representational capacity of equivalent impedance was verified through a drilling test, which showed five drilling stages could be divided using the established model. Furthermore, based on the mutation characteristic of equivalent impedance near the material interface, a threshold-based interface recognition algorithm was promoted. Modification of process parameters was also realized with a communication program. Finally, the self-adaptive drilling experiments were conducted. An average recognition depth error of 3.25% was observed, which meant the average thickness of 0.325 mm of the CFRP/Al stack was influenced by system response delay. The stability of the self-adaptive drilling system was verified under severe tool wear. The standard deviation of the recognition depth error was 0.112 mm. Compared with conventional vibration-assisted drilling, diameter deviation and surface quality of holes were considerably improved by 68.1% and 35.0%, respectively.

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Funding

The work in this paper was supported by the National Natural Science Foundation of China (NSFC) under grant number 51675277 and by the High-level Talents Project of the “six talents summit” in Jiangsu under grant number GDZB-011.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Xin Hu, Chen Zhang, Shengcai Wang, Fuhang Yu & Zixuan Wang

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  1. Xin Hu
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  2. Chen Zhang
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  3. Shengcai Wang
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  4. Fuhang Yu
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  5. Zixuan Wang
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Contributions

Methodology and formal analysis were performed by Xin Hu; the first draft of the manuscript was written by Xin Hu, and all authors commented on previous versions of the manuscript. Supervision, resources preparation, and conceptualization were performed by Chen Zhang. Investigation and data curation were performed by Shengcai Wang. Validation was performed by Fuhang Yu and Zixuan Wang. The revision was performed by Xin Hu. All authors read and approved the final manuscript.

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Correspondence to Chen Zhang.

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Hu, X., Zhang, C., Wang, S. et al. Investigation of self-adaptive drilling of CFRP/Al stacks based on equivalent impedance recognition of the vibration-assisted device. Int J Adv Manuf Technol 123, 1641–1656 (2022). https://doi.org/10.1007/s00170-022-10267-3

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