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High-speed drilling mechanism study of unidirectional CoCrFeNiAl fiber-reinforced aluminum matrix composites

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Abstract

Fiber-reinforced aluminum matrix composites have a wide range of application prospects in aerospace, automotive, and other fields. In order to further optimize the processing technology and improve the processing efficiency, the high-speed drilling mechanism of FeCoNiCrAl high-entropy alloy fiber-reinforced 7050 aluminum matrix composites was investigated in this study. A composite plate composed of three-layer unidirectional fiber-reinforced composite was constructed by using ABAQUS finite element software. The effects of different bit geometry parameters and drilling parameters on drilling force, stress–strain, and subsurface damage were studied during high-speed drilling. The results show that the drilling force is positively correlated with the feed speed and decreases with the increase of the spindle speed. The drilling force is positively correlated with spiral angle and negatively correlated with top angle. With the increase of feed speed, the area of the height stress area of the inlet and outlet increases first and then decreases, and the maximum point is 450 mm/s and 400 mm/s, respectively. With the increase of spindle speed, the area of the entrance layer increased first and then decreased. The area of the entrance layer was the largest when the spindle speed was 600 r/s, and the area of the outlet layer increased with the spindle speed. When the screw angle is 40° and the top angle is 90°, the main cutting edge of the bit drills out the whole plate, the processing quality of the drilling is relatively best. With the increase of spiral angle, the subsurface damage range of fiber at the inlet and outlet layer decreases. As the top angle increases, the damage range increases first and then decreases, showing a peak trend. With the increase of feed speed, the damage range decreases first and then increases. The damage range increases significantly with the increase of spindle speed.

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Funding

The work was supported by the National Natural Science Foundation of China (51705270), the National Natural Science Foundation of China (No. 51575289), the Natural Science Foundation of Guangdong Province (No. 2023A1515030171), the Science and Technology Project of Zhanjiang City, Guangdong Province (No. 2022A01004), the Natural Science Foundation of Shandong Province (No. ZR2016EEP03), the Applied Basic Research Program of Qingdao City (No. 19–6-2–69-cg), and the Shandong Qingchuang Science and Technology Project (No. 2019KJB022).

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Authors and Affiliations

  1. College of Mechanical and Power Engineering, Guangdong Ocean University, Zhanjiang, China

    Ping Zhang, Shunxiang Wang, Jinlong Zhang, Yajie Sun & Hanping Zhou

  2. College of Intelligent Manufacturing, Qingdao Huanghai University, Qingdao, 266520, China

    Ping Zhang & Xiujie Yue

  3. College of Intelligent Manufacturing, Qingdao University of Technology, Qingdao, 266520, China

    Xiujie Yue

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  1. Ping Zhang
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  2. Shunxiang Wang
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  3. Jinlong Zhang
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Contributions

The design of the overall scheme was completed by Zhang Ping. The design of the simulation scheme was completed by Zhang Jinlong and Sun Yajie. Data extraction was completed by Zhou Hanping and Yue Xiujie. Language modification was completed by Wang Shunxiang.

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Correspondence to Ping Zhang.

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Zhang, P., Wang, S., Zhang, J. et al. High-speed drilling mechanism study of unidirectional CoCrFeNiAl fiber-reinforced aluminum matrix composites. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13749-8

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