Skip to main content
SpringerLink
Log in

Wear behavior and machining quality of novel high-sharp brazed diamond abrasive core drills during drilling SiCf/SiC composite micro-holes

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

Abstract

SiCf/SiC composites have promising applications in aerospace industries. SiCf/SiC composite micro-holes are important components, such as gas film holes on turbine blades. However, micro-hole machining in the SiCf/SiC composite is challenging because of its excellent mechanical and physical properties and poor machinability caused by micro-hole constraints. Therefore, a novel brazed diamond abrasive core drill was designed to achieve high self-sharpness by continuously losing blunt diamond grits and exposing sharp diamond grits. The wear and self-sharpness of the developed drill were investigated and compared with those of an electroplated diamond core drill during ultrasonic vibration-assisted drilling of SiCf/SiC composite micro-holes. The material removal behaviors of SiCf/SiC composites, including drilling forces, exit tearing, hole dimensions, hole wall quality, and the wear of core drills, were also studied. The developed core drill demonstrated reduced drilling force and a significantly prolonged lifetime. Further, it achieved superior drilling performance, drilling accuracy, and micro-hole quality.

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

Similar content being viewed by others

Data availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

Code availability

This is not applicable.

References

  1. Li HH, Yuan XY, Zhao PH, Ping ZY, Liu Y, Guo SW (2023) A synergistic strategy for SiC/C nanofibers@MXene with core-sheath microstructure toward efficient electromagnetic wave absorption and photothermal conversion. Appl Surf Sci 613:155998. https://doi.org/10.1016/j.apsusc.2022.155998

    Article  Google Scholar 

  2. Lü XX, Li LB, Sun JJ, Yang JH, Jiao J (2022) Microstructure and tensile behavior of (BN/SiC)n coated SiC fibers and SiC/SiC minicomposites. J Eur Ceram Soc 43(5):1828–1842. https://doi.org/10.1016/j.jeurceramsoc.2022.12.032

    Article  Google Scholar 

  3. Zhang XH, Gao HS, Wen ZX, Li MY, Zhou XG, Yue ZF (2020) Effect of film cooling holes on the mechanical properties of 3D braided SiCf/SiC composites at 1350°C in air. Ceram Int 46(6):7982–7990. https://doi.org/10.1016/j.ceramint.2019.12.020

    Article  Google Scholar 

  4. Wang X, Ding WF, Zhao B (2022) A review on machining technology of aero-engine casings. J Adv Manuf Sci Technol 2(3):2022011–2022011. https://doi.org/10.51393/j.jamst.2022011

  5. An QL, Chen J, Ming WW, Chen M (2021) Machining of SiC ceramic matrix composites: a review. Chin J Aeronaut 34(4):540–567. https://doi.org/10.1016/j.cja.2020.08.001

    Article  Google Scholar 

  6. Wang F, Luo JJ, Li M, Deng Y (2014) A study on the technical method of drilling micro holes on new CMC-SiC with femtosecond laser. Appl Mech Mater 543–547:3924–3930. https://doi.org/10.4028/www.scientific.net/AMM.543-547.3924

    Article  Google Scholar 

  7. Zhang J, Liu RJ, Jian YJ, Wan F, Wang YF (2022) Degradation mechanism of SiCf/SiC composites after long-time water vapor and oxygen corrosion at 1300°C. Corros Sci 197:110099. https://doi.org/10.1016/j.corsci.2022.110099

    Article  Google Scholar 

  8. Wang D, Cao HR (2022) A comprehensive review on crack modeling and detection methods of aero-engine disks. J Adv Manuf Sci Technol 2(3):2022012–2022012. https://doi.org/10.51393/j.jamst.2022012

  9. Zeng JH, Zhang QL, Zhao J, Cai YB, Chu CL, Zhu YD, Xu JH (2022) The formed surface characteristics of SiCf/SiC composite in the nanosecond pulsed laser ablation. Ceram Int 48(24):36860–36870. https://doi.org/10.1016/j.ceramint.2022.08.251

    Article  Google Scholar 

  10. Huang B, Wang WH, Jiang RS, Xiong YF, Liu C (2022) Experimental study on ultrasonic vibration–assisted drilling micro-hole of SiCf/SiC ceramic matrix composites. Int J Adv Manuf Technol 120:8031–8044. https://doi.org/10.1007/s00170-022-09186-0

    Article  Google Scholar 

  11. Hasan M, Zhao JW, Jiang ZY (2017) A review of modern advancements in micro drilling techniques. J Manuf Process 29:343–375. https://doi.org/10.1016/j.jmapro.2017.08.006

    Article  Google Scholar 

  12. Chen J, An QL, Ming WW, Chen M (2019) Hole exit quality and machined surface integrity of 2D Cf/SiC composites drilled by PCD tools. J Eur Ceram Soc 39(14):4000–4010. https://doi.org/10.1016/j.jeurceramsoc.2019.05.057

    Article  Google Scholar 

  13. Wang J, Zhang YH, Liu YS, Fang H, Cao LY, Dong N, Luo R, Cheng GH, Cao YJ, Zhang Q (2023) Effect of SiC/SiC composites density on nanosecond-laser machining behaviors. Ceram Int 49(3):5199–5208. https://doi.org/10.1016/j.ceramint.2022.10.038

    Article  Google Scholar 

  14. Li WN, Zhang RH, Liu YS, Wang CH, Wang J, Yang XJ, Cheng LF (2016) Effect of different parameters on machining of SiC/SiC composites via pico-second laser. Appl Surf Sci 364:378–387. https://doi.org/10.1016/j.apsusc.2015.12.089

    Article  Google Scholar 

  15. Chen J, An QL, Gong QH, Zeng DB, Chen M (2022) Machinability improvement in milling of SiCf/SiC composites based on laser controllable ablation pretreatment. J Eur Ceram Soc 43(4):1352–1365. https://doi.org/10.1016/j.jeurceramsoc.2022.11.070

    Article  Google Scholar 

  16. Kumar SS, Thrinadh J, Datta S (2021) Parametric studies on SiC-abrasive jet assisted machining of alumina ceramics. Mater Today Proc 44:1643–1652. https://doi.org/10.1016/j.matpr.2020.11.823

    Article  Google Scholar 

  17. Zhang YF, Liu D, Zhang WJ, Zhu HT, Huang CZ (2022) Hole characteristics and surface damage formation mechanisms of Cf/SiC composites machined by abrasive waterjet. Ceram Int 48(4):5488–5498. https://doi.org/10.1016/j.ceramint.2021.11.093

    Article  Google Scholar 

  18. Zhang YB, Li WY, Tang LZ, Li CH, Liang XL, Xu SQ, Zafar S, Shubham S, Chen Y, Liu B, Zhou ZM (2023) Abrasive water jet tool passivation: from mechanism to application. J Adv Manuf Sci Technol 3(1):2022018–2022018. https://doi.org/10.51393/j.jamst.2022018

  19. Dong XY, Shin YC (2017) Improved machinability of SiC/SiC ceramic matrix composite via laser-assisted micromachining. Int J Adv Manuf Technol 90:731–739. https://doi.org/10.1007/s00170-016-9415-5

    Article  Google Scholar 

  20. Zhai ZY, Wang WJ, Mei XS, Li M, Cui JL, Wang FC, Pan AF (2018) Effect of the surface microstructure ablated by femtosecond laser on the bonding strength of EBCs for SiC/SiC composites. Opt Commun 424:137–144. https://doi.org/10.1016/j.optcom.2018.04.055

    Article  Google Scholar 

  21. Zhang RH, Li WN, Liu YS, Wang CH, Wang J, Yang XJ, Cheng LF (2015) Machining parameter optimization of C/SiC composites using high power picosecond laser. Appl Surf Sci 330:321–331. https://doi.org/10.1016/j.apsusc.2015.01.010

    Article  Google Scholar 

  22. Liu C, Zhang XZ, Gao L, Jiang XG, Li C, Yang T (2021) Feasibility of micro-hole machining in fiber laser trepan drilling of 2.5D Cf/SiC composite: experimental investigation and optimization. Optik (Stuttg) 242:167186. https://doi.org/10.1016/j.ijleo.2021.167186

    Article  Google Scholar 

  23. Detwiler KN, Opila EJ (2022) Oxidation of SiC/BN/SiC ceramic matrix composites in dry and wet oxygen at intermediate temperatures. J Eur Ceram Soc 42(10):4110–4120. https://doi.org/10.1016/j.jeurceramsoc.2022.04.003

    Article  Google Scholar 

  24. Sheikh-Ahmad JY (2016) Hole quality and damage in drilling carbon/epoxy composites by electrical discharge machining. Mater Manuf Process 31:941–950. https://doi.org/10.1080/10426914.2015.1048368

    Article  Google Scholar 

  25. Wei CJ, Zhao L, Hu DJ, Ni J (2013) Electrical discharge machining of ceramic matrix composites with ceramic fiber reinforcements. Int J Adv Manuf Technol 64:187–194. https://doi.org/10.1007/s00170-012-3995-5

    Article  Google Scholar 

  26. Hrechuk A, Bushlya V, M’Saoubi R, Ståhl JE (2018) Experimental investigations into tool wear of drilling CFRP. Procedia Manuf 25:294–301. https://doi.org/10.1016/j.promfg.2018.06.086

    Article  Google Scholar 

  27. Li PN, Qiu XY, Li CP, Niu QL, Chen AH, Ko TJ (2019) Hole exit damage and tool wear during the drilling of CFRP with a double-point angle drill. J Mech Sci Technol 33:2363–2370. https://doi.org/10.1007/s12206-019-0436-5

    Article  Google Scholar 

  28. Zhang BY, Sui TY, Lin B, Zheng W, Li SP, Fang S, Huang Y, Feng YQ (2022) Drilling process of Cf/SiC ceramic matrix composites: cutting force modeling, machining quality and PCD tool wear analysis. J Mater Process Technol 304:117566. https://doi.org/10.1016/j.jmatprotec.2022.117566

    Article  Google Scholar 

  29. Zou F, Chen J, An QL, Cai XJ, Chen M (2020) Influences of clearance angle and point angle on drilling performance of 2D Cf/SiC composites using polycrystalline diamond tools. Ceram Int 46(4):4371–4380. https://doi.org/10.1016/j.ceramint.2019.10.161

    Article  Google Scholar 

  30. Wang X, Popov VL, Yu ZJ, Li YQ, Xu JK, Li Q, Yu HD (2022) Evaluation of the cutting performance of micro-groove-textured PCD tool on SiCp/Al composites. Ceram Int 48(21):32389–32398. https://doi.org/10.1016/j.ceramint.2022.07.182

    Article  Google Scholar 

  31. Ding K, Fu YC, Su HH, Chen Y, Yu XZ, Ding GZ (2014) Experimental studies on drilling tool load and machining quality of C/SiC composites in rotary ultrasonic machining. J Mater Process Technol 214(12):2900–2907. https://doi.org/10.1016/j.jmatprotec.2014.06.015

    Article  Google Scholar 

  32. He JY, Su HH, Qian N, Xu PF (2022) Machining performance analysis of rotary ultrasonic-assisted drilling of SiCf/SiC composites. Crystals 12(11):1658. https://doi.org/10.3390/cryst12111658

    Article  Google Scholar 

  33. Wang JJ, Feng PF, Zheng JZ, Zhang JF (2016) Improving hole exit quality in rotary ultrasonic machining of ceramic matrix composites using a compound step-taper drill. Ceram Int 42(12):13387–13394. https://doi.org/10.1016/j.ceramint.2016.05.095

    Article  Google Scholar 

  34. Tawakoli T, Azarhoushang B (2011) Intermittent grinding of ceramic matrix composites (CMCs) utilizing a developed segmented wheel. Int J Mach Tools Manuf 51(2):112–119. https://doi.org/10.1016/j.ijmachtools.2010.11.002

    Article  Google Scholar 

  35. Xue F, Zheng K, Liao WH, Shu J, Miao DD (2021) Experimental investigation on fatigue property at room temperature of C/SiC composites machined by rotary ultrasonic milling. J Eur Ceram Soc 41(6):3341–3356. https://doi.org/10.1016/j.jeurceramsoc.2021.01.046

    Article  Google Scholar 

  36. Feng PF, Wang JJ, Zhang JF, Zheng JZ (2017) Drilling induced tearing defects in rotary ultrasonic machining of C/SiC composites. Ceram Int 43(1):791–799. https://doi.org/10.1016/j.ceramint.2016.10.010

    Article  Google Scholar 

  37. Li Z, Yuan SM, Ma J, Shen J, Batako ADL (2022) Cutting force and specific energy for rotary ultrasonic drilling based on kinematics analysis of vibration effectiveness. Chin J Aeronaut 35(1):376–387. https://doi.org/10.1016/j.cja.2020.12.023

    Article  Google Scholar 

  38. Wu BF, Zhao B, Ding WF, Su HH (2021) Investigation of the wear characteristics of microcrystal alumina abrasive wheels during the ultrasonic vibration-assisted grinding of PTMCs. Wear 477:203844. https://doi.org/10.1016/j.wear.2021.203844

    Article  Google Scholar 

  39. Sonia P, Jain JK, Saxena KK (2021) Influence of ultrasonic vibration assistance in manufacturing processes: a review. Mater Manuf Process 36:1451–1475. https://doi.org/10.1080/10426914.2021.1914843

    Article  Google Scholar 

  40. Su QT, Li XD, Lu Y, Huang S (2022) Designing an ultrasonic array device to transport space particle suspension. J Adv Manuf Sci Technol 2(1):2022004–2022004. https://doi.org/10.51393/j.jamst.2022004

  41. Wang MX, Yu HD, Xu JK, Chen GJ, Dai B, Wang S (2021) Amplitude effect on micro-hole drilling of 3D needled Cf/SiC by ultrasonic vibration. Ceram Int 47(24):34987–35001. https://doi.org/10.1016/j.ceramint.2021.09.040

    Article  Google Scholar 

  42. Yang YK, Zheng K, Dong S, Sun LJ, Sun ZW (2023) Investigation into temperature and its effects on hole wall quality in rotary ultrasonic countersinking of thin-walled CFRP/Al stacks. J Adv Manuf Sci Technol 3(2):2023002–2023002. https://doi.org/10.51393/j.jamst.2023002

  43. Ding K, Li QL, Lei WN, Zhang CD, Xu MZ, Wang X (2022) Design of a defined grain distribution brazed diamond grinding wheel for ultrasonic assisted grinding and experimental verification. Ultrasonics 118:106577. https://doi.org/10.1016/j.ultras.2021.106577

    Article  Google Scholar 

  44. Zou ZC, He L, Zhou T, Zhang WQ, Tian PF, Zhou XR (2023) Research on inverse identification of Johnson-Cook constitutive parameters for turning 304 stainless steel based on coupling simulation. J Mater Res Technol 23:2244–2262. https://doi.org/10.1016/j.jmrt.2023.01.090

    Article  Google Scholar 

Download references

Funding

The authors gratefully acknowledge the support of National Natural Science Foundation of China (Nos. 92060203 and 52205476), Science Center for Gas Turbine Project (No. P2022-AB-IV-002–001), and Outstanding Postdoctoral Program of Jiangsu Province (No. 2022ZB204).

Author information

Authors and Affiliations

  1. Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Jingyuan He, Ning Qian, Honghua Su, Yucan Fu, Wenfeng Ding & Jiuhua Xu

  2. JITRI Institute of Precision Manufacturing, Nanjing, 211806, China

    Ning Qian

Authors
  1. Jingyuan He
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Ning Qian
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Honghua Su
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Yucan Fu
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Wenfeng Ding
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jiuhua Xu
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Jingyuan He and Ning Qian contributed to the conception of the study. Jingyuan He performed the experiments. Honghua Su, Wenfeng Ding, and Ning Qian contributed significantly to analysis and manuscript preparation. Jingyuan He performed the data analyses and wrote the manuscript. Yucan Fu and Jiuhua Xu helped perform the analysis with constructive discussions.

Corresponding authors

Correspondence to Ning Qian or Honghua Su.

Ethics declarations

Ethics approval

The article follows the guidelines of the Committee on Publication Ethics (COPE) and involves no studies on human or animal subjects.

Consent to participate

This is not applicable.

Consent for publication

This is 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

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

He, J., Qian, N., Su, H. et al. Wear behavior and machining quality of novel high-sharp brazed diamond abrasive core drills during drilling SiCf/SiC composite micro-holes. Int J Adv Manuf Technol 128, 3801–3816 (2023). https://doi.org/10.1007/s00170-023-12146-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-023-12146-x

Keywords

Search

Navigation