CFRP Drilling Model: Fiber Orientation Influence on Mechanical Load and Delamination

Abstract:

This paper presents a combined experimental and theoretical investigation and proposes a mechanical load modeling of a multidirectional layer CFRP drilling to avoid fibers delamination by a better choice of their orientations. A first step consists in working with unidirectional CFRP to correlate cutting mode (opening, shear and bending) with force level depending on the angular tool position. The discretisation of the cutting edge is employed to know the exact contribution of each elementary part of the edge, resulting in a complete drill operation modeling (tip penetration, full engagement and exit). A second step consists in using this unidirectional approach to model a multidirectional layer CFRP drilling. In this case, layers are cut simultaneously which induce brutal mechanical load variation. A summation method is used to estimate the force level depending on fiber arrangement. Optimal orientation combinations are underlined by this approach, in order to improve the CFRP design, by considering the manufacturing concerns.

• Periodical: Advanced Materials Research (Volume 223)
• Pages: 111-121
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.223.111
• Online since: April 2011
• Authors: Cedric Bonnet, Brahim Benmohammed, Gérard Poulachon, Joël Rech, Yannick Girard
• Keywords: A Virtual Drilling Simulation, Better Choice of Fibers Orientation, CFRP Drilling Model, Drilling Torque M_Z, Fibers Delamination, Mechanical Load Modeling

References

[1] C. Bonnet: Compréhension des mécanismes de coupe lors du perçage à sec de l'empilage Ti6Al4V/Composite fibre de carbone, Thèse de doctorat, Arts et Métiers ParisTech, centre de cluny, (2010).

[2] V. Chandrasekharan, S.G. Kapoor and DeVor R.E.: A mechanistic approach to predicting the cutting forces in drilling: with application to fiber-reinforced composite materials, Journal of engineering for industry, Transactions ASME, Vol. 117, pp.559-570, (1995).

DOI: 10.1115/1.2803534

[3] Y. Gong, C.L. Kornel and F. Ehmann: Dynamics of Initial Penetration in Drilling: Part 1-Mechanistic Model for Dynamic Forces: Journal of Manufacturing Science and Engineering, Transactions of the ASME Vol. 127 (MAY 2005), pp.280-288.

DOI: 10.1115/1.1852569

[4] H. Ho-cheng and C.C. Tsao: The path towards delamination-free drilling of composite materials: Journal of materials processing technology Vol. 167 (2005), pp.251-264.

DOI: 10.1016/j.jmatprotec.2005.06.039

[5] E. Kimivaa in: Cutting force in wood working, Helsinki (1950).

[6] S. C. Lin and I.K. Chen: drilling carbon fiber-reinforced composite material at high speed: Wear Vol. 194 (1996), pp.156-162.

DOI: 10.1016/0043-1648(95)06831-7

[7] W.M. McKenzie in: Fundamental aspects of the wood cutting process: Forest Products Journal 10 (1960), pp.447-456.

[8] A. Mondelin, B. Furet and J. Rech: Characterisation of friction properties between a laminated carbon fibers reinforced polymer and a monocrystalline diamond under dry or lubricated conditions: Tribology international, Vol. 43-9 (2010).

DOI: 10.1016/j.triboint.2010.03.015

[9] A. Thangaraj and M. Langenstein: An Investigation Into the Relationships Between Hole Quality and Drilling Forces: Proceedings of Manufacturing International, Part 4: Advances in Materials and Automation Vol. 4 (1990), pp.149-157.

[10] A. Velayudham and R. Krishnamurthy: Effect of point geometry and their influence on thrust and delamination in drilling of polymeric composites: Journal of Materials Processing Technology Vol. 185 (2007), p.204–209.

DOI: 10.1016/j.jmatprotec.2006.03.146

[11] W. Koenig, C. Wulf, P. Grass and H. Willerscheid: Machining of fiber reinforced plastics: Annals of the CIRP Vol. 34-2 (1985), p.538–548.

DOI: 10.1016/s0007-8506(07)60186-3

[12] R. Zitoune, F. Collombet, F. Lachaud and R. Piquet: Experiment-calculation comparison of the cutting conditions representative of the long fiber composite drilling phase: Composites Science and Technology Vol. 65 (2005), p.455–466.

DOI: 10.1016/j.compscitech.2004.09.028

[13] http: /news. thomasnet. com/fullstory: Drill-is-designed-for-aerospace-CFRP-cutting applications, June 25 (2007), Kennametal Inc. Latrobe, PA.

[14] http: /www. sae. org/mags/AEM/5907: Kannemetal makes the cut on composites, 19 Février (2009).

[15] M. Denford in: Drill Delates Delamination in CFRP, Modern Machine Shop, Editor, MMS Online, Gardner Publications, Inc. (2010).

[16] Modern Machine Shop in: English university acquires laser for cutting carbon fiber composites: New item from Composites world, MMS Online, Gardner Publications, Inc. (2010).