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Experimental study on hole characteristics and surface integrity following abrasive waterjet drilling of Ti6Al4V/CFRP hybrid stacks

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Abstract

Abrasive waterjet (AWJ) technology has been demonstrated to be a feasible manufacturing process for machining composite and titanium alloys to its specific advantages. However, AWJ cutting of composite/metallic hybrid stacks possesses several challenges. In this work, experimental results were analyzed including hole quality and surface morphology/integrity during abrasive waterjet drilling of Ti6Al4V/CFRP stacks with different operating conditions. The influence of some key parameters involving traverse speed, hydraulic pressure, stand-off distance, and stack layup on hole quality was studied. Experimental array having 16 trials was designed based on full-factorial statistical analysis. Results showed that hole edge rounding was prevalent at the entrance irrespective of processing parameters due to erosion effect of abrasive particles. Ti6Al4V/CFRP layup configuration was preferred to obtain better geometrical consistency in terms of hole diameter. The variation of hole roundness was relatively high (up to 0.57 mm) when drilling hybrid stacks with Ti6Al4V/CFRP configuration. Ridges, fractured fibers, and small voids were generally observed on CFRP surface, while wear tracks and embedded fractured particles were typically found on titanium surface due to various material removal mechanisms.

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Funding

This work was supported by the Fundamental Research Funds for the Central Universities (531107050870) and Hunan Provincial Natural Science Foundation of China (2019JJ50053).

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Authors and Affiliations

  1. State Key Laboratory of Advanced Design and Manufacture for Vehicle Body, Hunan University, Changsha, 410082, China

    Maojun Li, Mingjie Huang, Yiwei Chen, Wei Kai & Xujing Yang

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  1. Maojun Li
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  2. Mingjie Huang
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  3. Yiwei Chen
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Correspondence to Xujing Yang.

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Li, M., Huang, M., Chen, Y. et al. Experimental study on hole characteristics and surface integrity following abrasive waterjet drilling of Ti6Al4V/CFRP hybrid stacks. Int J Adv Manuf Technol 104, 4779–4789 (2019). https://doi.org/10.1007/s00170-019-04334-5

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