Effect of Support Distance on Damage of Drilled Thin CFRP Laminates
Severe damages may occur during the drilling of carbon fiber reinforced plastics (CFRP). In practice, this damage is limited by adding a backup support to the drilled parts. For some aeronautical parts with curvatures, backing up parts is a demanding process. In order to simplify the operation, this research studies the effect of using a configurable setup to support parts on the resulting quality of drilled holes. The test coupons referenced in this study are twenty four-plies unidirectional laminates made of carbon fibers and epoxy resin. Different signals were measured during the drilling process for these laminates, including the thrust force, the displacement and the acceleration. The processing of these signals demonstrated that the damage is due to the combination of two main factors: the spring-back of the thin part and the thrust force. The results found were confirmed for different feeds and speeds. When the distance between supports is increased, it is observed that the spring-back increases but the thrust force decreases. The study proves the feasibility of unsupported drilling of thin CFRP laminates without creating any observable damage.
[1] C. C. Tsao et H. Hocheng, “Effects of exit back-up on delamination in
drilling composite materials using a saw drill and a core drill”,
International Journal of Machine Tools & Manufacture, vol.45,
P.1261–1270, 2005.
[2] W. Koenig, P. Graß, “Quality definitions and assessment in drilling of
fibre reinforced thermosets”, Annals of the CIRP, vol. 38, pp.119–124,
1989.
[3] A. B. Sadat, W.S. Chan, and B.P. Wang, “Delamination of
graphite/epoxy laminate during drilling operation”, Journal of Energy
Resources Technology, Transactions of the ASME, vol. 114, no. 2: pp.
139-141, 1992.
[4] R. Teti, “Machining of composite materials”, CIRP Annals -
Manufacturing Technology, vol. 51, no. 2, pp. 611-634, 2002.
[5] F. Lachaud, R. Piquet, F. Collombet and L. Surcin. “Drilling of
composite structures”, Composite Structures, vol. 52, pp.511-516, 2001.
[6] C. K. H Dharan, M. S. Won, “Machining parameters for an intelligent
machining system for composite laminates”, International Journal of
Machine Tools & Manufacture, vol. 40, no. 3, pp. 415-26, 2000.
[7] H. Hocheng and C. K. H. Dharan, “Delamination during drilling in
composite laminates”. Journal of engineering for industry, vol. 112,
pp.236-239, 1990
[8] J-F. Chatelain J-F, I. Zaghbani, “A Comparison of Special Helical Cutter
Geometries Based on Cutting Forces for the Trimming of CFRP
Laminates”, NAUN International Journal of Mechanics, vol. 6, no. 1, pp.
52-59, 2012.
[9] H. Hamedanianpour, J-F. Chatelain, “Effect of Tool Wear on Quality of
Carbon Fiber Reinforced Polymer Laminate during Edge Trimming”,
Advanced MaterialsResearch Journal, to be published, 2013.
[10] H. Hocheng, C. C. Tsao, “Comprehensive analysis of delamination in
drilling of composite materials with various drill bits”, Journal of
Materials Processing Technology, vol. 140, no. 1-3, pp. 335-339, 2003.
[11] H. Hocheng, C. C. Tsao, “The path towards delamination-free drilling of
composite materials”, Journal of Materials Processing Technology, vol.
167, no. 2-3, pp. 251-264, 2005.
[12] S. Gouleau, S. Garnier, B. Furet, “Perçage d’empilages multimatériaux”,
Mécanique et Industries, vol. 8, no. 5, pp. 463-469, 2007.
[13] C. Murphy, G. Byrne, M. D. Gilchrist, “The performance of coated
tungsten carbide drills when machining carbon fibre-reinforced epoxy
composite materials”, Proc. of the Institution of Mechanical Engineers,
Part B: Journal of Engineering Manufacture, vol. 216, no. 2, pp. 143-
152, 2002.
[14] Tsao, W.-C. Chen, “Prediction of the location of delamination in the
drilling of composite laminates”, Journal of. Materials. Processing.
Technology vol. 70, pp. 185–189, 1997.
[15] G. DiPaolo, S.G. Kapoor, R.E. DeVor, “An experimental investigation of
the crack growth phenomenon for drilling of fibre-reinforced composite
materials”, Journal of engineering for industry. Transactions of the
ASME, vol. 118, pp.104–110, 1996.
[16] E. Capello, “Damping and its effect on delamination damage in drilling
thin composite laminates”, Journal of Materials Processing Technology,
vol 148, no. 2, pp. 186–195, 2004.
[1] C. C. Tsao et H. Hocheng, “Effects of exit back-up on delamination in
drilling composite materials using a saw drill and a core drill”,
International Journal of Machine Tools & Manufacture, vol.45,
P.1261–1270, 2005.
[2] W. Koenig, P. Graß, “Quality definitions and assessment in drilling of
fibre reinforced thermosets”, Annals of the CIRP, vol. 38, pp.119–124,
1989.
[3] A. B. Sadat, W.S. Chan, and B.P. Wang, “Delamination of
graphite/epoxy laminate during drilling operation”, Journal of Energy
Resources Technology, Transactions of the ASME, vol. 114, no. 2: pp.
139-141, 1992.
[4] R. Teti, “Machining of composite materials”, CIRP Annals -
Manufacturing Technology, vol. 51, no. 2, pp. 611-634, 2002.
[5] F. Lachaud, R. Piquet, F. Collombet and L. Surcin. “Drilling of
composite structures”, Composite Structures, vol. 52, pp.511-516, 2001.
[6] C. K. H Dharan, M. S. Won, “Machining parameters for an intelligent
machining system for composite laminates”, International Journal of
Machine Tools & Manufacture, vol. 40, no. 3, pp. 415-26, 2000.
[7] H. Hocheng and C. K. H. Dharan, “Delamination during drilling in
composite laminates”. Journal of engineering for industry, vol. 112,
pp.236-239, 1990
[8] J-F. Chatelain J-F, I. Zaghbani, “A Comparison of Special Helical Cutter
Geometries Based on Cutting Forces for the Trimming of CFRP
Laminates”, NAUN International Journal of Mechanics, vol. 6, no. 1, pp.
52-59, 2012.
[9] H. Hamedanianpour, J-F. Chatelain, “Effect of Tool Wear on Quality of
Carbon Fiber Reinforced Polymer Laminate during Edge Trimming”,
Advanced MaterialsResearch Journal, to be published, 2013.
[10] H. Hocheng, C. C. Tsao, “Comprehensive analysis of delamination in
drilling of composite materials with various drill bits”, Journal of
Materials Processing Technology, vol. 140, no. 1-3, pp. 335-339, 2003.
[11] H. Hocheng, C. C. Tsao, “The path towards delamination-free drilling of
composite materials”, Journal of Materials Processing Technology, vol.
167, no. 2-3, pp. 251-264, 2005.
[12] S. Gouleau, S. Garnier, B. Furet, “Perçage d’empilages multimatériaux”,
Mécanique et Industries, vol. 8, no. 5, pp. 463-469, 2007.
[13] C. Murphy, G. Byrne, M. D. Gilchrist, “The performance of coated
tungsten carbide drills when machining carbon fibre-reinforced epoxy
composite materials”, Proc. of the Institution of Mechanical Engineers,
Part B: Journal of Engineering Manufacture, vol. 216, no. 2, pp. 143-
152, 2002.
[14] Tsao, W.-C. Chen, “Prediction of the location of delamination in the
drilling of composite laminates”, Journal of. Materials. Processing.
Technology vol. 70, pp. 185–189, 1997.
[15] G. DiPaolo, S.G. Kapoor, R.E. DeVor, “An experimental investigation of
the crack growth phenomenon for drilling of fibre-reinforced composite
materials”, Journal of engineering for industry. Transactions of the
ASME, vol. 118, pp.104–110, 1996.
[16] E. Capello, “Damping and its effect on delamination damage in drilling
thin composite laminates”, Journal of Materials Processing Technology,
vol 148, no. 2, pp. 186–195, 2004.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:65189", author = "Jean François Chatelain and Imed Zaghbani and Gilbert Lebrun and Kaml Hasni", title = "Effect of Support Distance on Damage of Drilled Thin CFRP Laminates ", abstract = "Severe damages may occur during the drilling of carbon fiber reinforced plastics (CFRP). In practice, this damage is limited by adding a backup support to the drilled parts. For some aeronautical parts with curvatures, backing up parts is a demanding process. In order to simplify the operation, this research studies the effect of using a configurable setup to support parts on the resulting quality of drilled holes. The test coupons referenced in this study are twenty four-plies unidirectional laminates made of carbon fibers and epoxy resin. Different signals were measured during the drilling process for these laminates, including the thrust force, the displacement and the acceleration. The processing of these signals demonstrated that the damage is due to the combination of two main factors: the spring-back of the thin part and the thrust force. The results found were confirmed for different feeds and speeds. When the distance between supports is increased, it is observed that the spring-back increases but the thrust force decreases. The study proves the feasibility of unsupported drilling of thin CFRP laminates without creating any observable damage.
", keywords = "CFRP, Damage, Drilling, Flexible setup.", volume = "7", number = "9", pages = "1863-5", }
