Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack
Drilling two different materials in a layer, or stack-up, is being practiced widely in the aerospace industry to minimize critical dimension mismatch and error in the subsequent assembly process, but the compatibility of the drill to compensate the widely differing properties of composite is still a...
Main Authors: | , , , , |
---|---|
Format: | Article |
Language: | English |
Published: |
MDPI AG
2021-07-01
|
Series: | Journal of Composites Science |
Subjects: | |
Online Access: | https://www.mdpi.com/2504-477X/5/7/189 |
id |
doaj-2aec2756848143a9b2da7d27847cf982 |
---|---|
record_format |
Article |
spelling |
doaj-2aec2756848143a9b2da7d27847cf9822021-07-23T13:48:29ZengMDPI AGJournal of Composites Science2504-477X2021-07-01518918910.3390/jcs5070189Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite StackMuhammad Hafiz Hassan0Jamaluddin Abdullah1Gérald Franz2Chim Yi Shen3Reza Mahmoodian4School of Mechanical Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, Pulau Pinang, MalaysiaSchool of Mechanical Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, Pulau Pinang, MalaysiaLaboratoire des Technologies Innovantes, UR UPJV 3899, Avenue des Facultés, Le Bailly, 80025 Amiens, FranceSchool of Mechanical Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, Pulau Pinang, MalaysiaSchool of Mechanical Engineering, Universiti Sains Malaysia, Nibong Tebal 14300, Pulau Pinang, MalaysiaDrilling two different materials in a layer, or stack-up, is being practiced widely in the aerospace industry to minimize critical dimension mismatch and error in the subsequent assembly process, but the compatibility of the drill to compensate the widely differing properties of composite is still a major challenge to the industry. In this paper, the effect of customized twist drill geometry and drilling parameters are being investigated based on the thrust force signature generated during the drilling of CFRP/Al7075-T6. Based on ANOVA, it is found that the maximum thrust force for both CFRP and Al7075-T6 are highly dependent on the feed rate. Through the analysis of maximum thrust force, supported by hole diameter error, hole surface roughness, and chip formation, it is found that the optimum tool parameters selection includes a helix angle of 30°, primary clearance angle of 6°, point angle of 130°, chisel edge angle of 30°, speed of 2600 rev/min and feed rate of 0.05 mm/rev. The optimum parameters obtained in this study are benchmarked against existing industry practice of the capability to produce higher hole quality and efficiency, which is set at 2600 rev/min for speed and 0.1 mm/rev for feed rate.https://www.mdpi.com/2504-477X/5/7/189single-shot drillingCFRP/Al stackthrust force signaturetwist drillsurface roughnesshole diameter |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Muhammad Hafiz Hassan Jamaluddin Abdullah Gérald Franz Chim Yi Shen Reza Mahmoodian |
spellingShingle |
Muhammad Hafiz Hassan Jamaluddin Abdullah Gérald Franz Chim Yi Shen Reza Mahmoodian Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack Journal of Composites Science single-shot drilling CFRP/Al stack thrust force signature twist drill surface roughness hole diameter |
author_facet |
Muhammad Hafiz Hassan Jamaluddin Abdullah Gérald Franz Chim Yi Shen Reza Mahmoodian |
author_sort |
Muhammad Hafiz Hassan |
title |
Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack |
title_short |
Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack |
title_full |
Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack |
title_fullStr |
Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack |
title_full_unstemmed |
Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack |
title_sort |
effect of twist drill geometry and drilling parameters on hole quality in single-shot drilling of cfrp/al7075-t6 composite stack |
publisher |
MDPI AG |
series |
Journal of Composites Science |
issn |
2504-477X |
publishDate |
2021-07-01 |
description |
Drilling two different materials in a layer, or stack-up, is being practiced widely in the aerospace industry to minimize critical dimension mismatch and error in the subsequent assembly process, but the compatibility of the drill to compensate the widely differing properties of composite is still a major challenge to the industry. In this paper, the effect of customized twist drill geometry and drilling parameters are being investigated based on the thrust force signature generated during the drilling of CFRP/Al7075-T6. Based on ANOVA, it is found that the maximum thrust force for both CFRP and Al7075-T6 are highly dependent on the feed rate. Through the analysis of maximum thrust force, supported by hole diameter error, hole surface roughness, and chip formation, it is found that the optimum tool parameters selection includes a helix angle of 30°, primary clearance angle of 6°, point angle of 130°, chisel edge angle of 30°, speed of 2600 rev/min and feed rate of 0.05 mm/rev. The optimum parameters obtained in this study are benchmarked against existing industry practice of the capability to produce higher hole quality and efficiency, which is set at 2600 rev/min for speed and 0.1 mm/rev for feed rate. |
topic |
single-shot drilling CFRP/Al stack thrust force signature twist drill surface roughness hole diameter |
url |
https://www.mdpi.com/2504-477X/5/7/189 |
work_keys_str_mv |
AT muhammadhafizhassan effectoftwistdrillgeometryanddrillingparametersonholequalityinsingleshotdrillingofcfrpal7075t6compositestack AT jamaluddinabdullah effectoftwistdrillgeometryanddrillingparametersonholequalityinsingleshotdrillingofcfrpal7075t6compositestack AT geraldfranz effectoftwistdrillgeometryanddrillingparametersonholequalityinsingleshotdrillingofcfrpal7075t6compositestack AT chimyishen effectoftwistdrillgeometryanddrillingparametersonholequalityinsingleshotdrillingofcfrpal7075t6compositestack AT rezamahmoodian effectoftwistdrillgeometryanddrillingparametersonholequalityinsingleshotdrillingofcfrpal7075t6compositestack |
_version_ |
1721287543625875456 |