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Experimental and scale-span numerical investigations in conventional and longitudinal torsional coupled rotary ultrasonic–assisted drilling of CFRPs

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Abstract

Longitudinal torsional coupled rotary ultrasonic–assisted drilling (LTC-RUAD) technology is introduced to improve the surface roughness of the hole-wall and solve the tear, burr, and delamination of carbon fiber–reinforced polymers (CFRPs) induced by large thrust force and torque during conventional drilling (CD). An experiment and scale-span numerical investigation of drilling CFRPs were presented for both the CD and LTC-RUAD processes in this study. A drilling experimental platform using the LTC-RUAD was built via a novel independently designed and manufactured LTC-RUAD vibration actuator, while the drilling experiments involving T700S-12 K/YP-H26 CFRP specimens with different process parameters were carried out by adopting the different ultrasonic vibration amplitude (UVA) in the longitudinal and torsional directions. Then, a three-dimensional (3D) scale-span FE simulation model of the CD and LTC-RUAD which applied the different UVA using tapered drill-reamer (TDR) is developed to find more details about the effects of machining quality of the holes. Experimental and simulation results revealed that the maximum average thrust force reduction is observed to be as high as 30% under certain drilling conditions, and the maximum average thrust force and the delamination factor of the drilled hole shows a “concave” trend with the increase of the UVA. The quality at the exit of the drilled hole is best when adopting Sr = 2000 rpm, Sf = 0.01 mm/rev, Alon = 7.02 μm, and Ator = 9.29 μm in the LTC-RUAD. The delamination factor is only 0.054, and the damage factors are reduced by 69.67% compared with CD.

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Acknowledgements

The authors would like to acknowledge the editors and the anonymous referees for their insightful comments.

Funding

Authors declare that we have no financial and personal relationships with other people or organizations that can inappropriately influence our work. The work reported herein is sponsored by the National Natural Science Foundation of China (52105450, 51605221, 51875283), the University Science Research Project of Jiangsu Province (No. 21KJB460016), the Aeronautical Science Foundation of China (2017ZE52052), and the National Commercial Aircraft Manufacturing Engineering Technology Research Center Innovation Foundation (COMAC-SFGS-2019-341).

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Authors and Affiliations

  1. College of Mechanical Engineering, Jiangsu University of Science and Technology, Zhenjiang, 212003, People’s Republic of China

    Yong Liu, Zitao Pan & Qiannan Li

  2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Yong Liu, Zhenchao Qi & Wenliang Chen

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  1. Yong Liu
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  2. Zitao Pan
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  3. Qiannan Li
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  4. Zhenchao Qi
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  5. Wenliang Chen
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Contributions

Yong Liu designed the study, performed the research, analyzed the data, and wrote the paper. Zitao Pan and Qiannan Li conducted experiments and data processing. Zhenchao Qi provided experimental condition and directed experiments. Wenliang Chen modified the paper.

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Correspondence to Yong Liu or Zhenchao Qi.

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Liu, Y., Pan, Z., Li, Q. et al. Experimental and scale-span numerical investigations in conventional and longitudinal torsional coupled rotary ultrasonic–assisted drilling of CFRPs. Int J Adv Manuf Technol 119, 1707–1724 (2022). https://doi.org/10.1007/s00170-021-08286-7

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  • DOI: https://doi.org/10.1007/s00170-021-08286-7

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