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Machining performance of PCD drill in low-frequency vibration-assisted drilling of CFRP/Ti6Al4V stack: with special emphasis on the plowing behavior

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Abstract

In low-frequency vibration-assisted drilling (LFVAD) of CFRP/Ti6Al4V stacks, owing to the different mechanical and thermal performances of the involved carbon fiber–reinforced plastic (CFRP) composite and Ti6Al4V alloy, the short tool life of commonly used carbide (WC) tools and rapidly deteriorated machining quality are the major problems. This paper aims to explore whether the polycrystalline diamond (PCD) tool can achieve a competitive effect on drilling CFRP/Ti6Al4V stacks compared with previous CFRP drilling studies. To avoid the frequent occurrence of chisel edge fracture in LFVAD of Ti6Al4V alloy, a model of plowing behavior is established and parametric experiments based on it are performed with both PCD and WC drills. It is found that the periodically dynamic force is the major factor causing the chisel edge fracture of the PCD drill, which can be alleviated by reducing the feed rate. Besides, by using PCD drills instead of WC drills in Ti6Al4V drilling, the exit burr height, drilling diameter deviation, and surface roughness value are reduced under each given parameter. Finally, PCD and WC drill bits are used to perform a wear test on the CFRP/Ti6Al4Vstacks under optimized parameters. The PCD drill achieves superior performance, including lower wear rate, better hole quality, and higher consistency. The experiments discussed in this paper provide some suggestions for selecting tools and cutting parameters when drilling CFRP/Ti6Al4V stacks.

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Data availability

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

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Not applicable.

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Funding

This work was financially supported by the National Natural Science Foundation of China (No. 51875284).

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Authors and Affiliations

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

    Chaoren Yan, Yan Chen, Ning Qian, Yijia Chen & Nan Guo

  2. MITIS SAS, 44340, Bouguenais, France

    Haojun Yang

  3. JITRI Institute of Precise Manufacturing Technology, Nanjing, 210016, China

    Haojun Yang & Ning Qian

  4. College of Energy and Power Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Ning Qian

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  1. Chaoren Yan
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  2. Yan Chen
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  6. Nan Guo
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Contributions

Chaoren Yan and Yan Chen contributed to the conception of the study.

Chaoren Yan and Yijia Chen performed the experiment.

Haojun Yang and Ning Qian contributed significantly to analysis and manuscript preparation.

Chaoren Yan performed the data analyses and wrote the manuscript.

Yan Chen and Haojun Yang helped perform the analysis with constructive discussions.

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Correspondence to Yan Chen.

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Yan, C., Chen, Y., Yang, H. et al. Machining performance of PCD drill in low-frequency vibration-assisted drilling of CFRP/Ti6Al4V stack: with special emphasis on the plowing behavior. Int J Adv Manuf Technol 116, 2269–2283 (2021). https://doi.org/10.1007/s00170-021-07603-4

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