Experimental studies on a two-step technique to reduce delamination damage during milling of large diameter holes in CFRP/Al stack
Experimental studies on a two-step technique to reduce delamination damage during milling of large diameter holes in CFRP/Al stack
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DOI：
10.1016/j.compstruct.2018.01.039
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发表时间：
2018
影响因子：
6.3
通讯作者：
Gongdong Wang;Melly Stephen Kirwa;Nan Li
中科院分区：
文献类型：
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作者：
Gongdong Wang;Melly Stephen Kirwa;Nan Li
非传统的制孔加工工艺正被用于在难以切割的材料如碳纤维增强聚合物（CFRP）复合材料中制造孔。在许多非传统工艺中，螺旋铣削仍然是传统钻孔的最佳替代方案。它具有切削力小、刀具磨损小、孔加工质量高等优点。复合材料与金属结合使用在航空航天工业中非常常见，最常见的配置是CFRP/Al和CFRP/Ti-6Al-4V。本文提出了CFRP/Al叠层螺旋铣削的两步加工工艺，并进行了实验研究，将实验结果与常规钻削工艺进行了比较。在第一步中，在CFRP/Al堆叠上从复合材料部件开始进行铣削，然后翻转工件，以便在第二步中在金属部件上开始铣削。结果表明，螺旋铣削减少约35%的轴向力相比，传统的钻。在第二步中所涉及的力被发现是约25%小于在螺旋铣削过程中的第一步。力的减小因此导致较少的损伤，如机加工孔的扫描电子显微镜（SEM）图像所示。
Non-conventional hole-making machining processes are being adopted to manufacture holes in the difficult to cut materials like carbon fiber reinforced polymer (CFRP) composites. Of the many non-conventional processes, helical milling remains the most favorable and the best alternative to conventional drilling. It possesses several advantages including low cutting forces, reduced tool wear and improved hole quality. The use of composites in conjunction with metals is very common in aerospace industry and the most common configurations are CFRP/Al and CFRP/Ti-6Al-4V. In this work, a two step process for helical milling in CFRP/Al stack is proposed and experimented then the results are compared with that of conventional drilling. In the first step, milling is done on the CFRP/Al stack starting on the composite part then the workpiece is flipped so that in the second step milling starts on the metal part. Results show that helical milling reduces axial forces by about 35% compared to that of conventional drilling. The forces involved in the second step were found to be about 25% less than that of the first step in the helical milling process. Reduction in forces consequently leads to less damage as scanning electron microscope (SEM) images of the machined holes show.