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Effect of Twist Drill Geometry and Drilling Parameters on Hole Quality in Single-Shot Drilling of CFRP/Al7075-T6 Composite Stack

Abstract : 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.
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https://hal-u-picardie.archives-ouvertes.fr/hal-03387802
Contributeur : Gérald Franz Connectez-vous pour contacter le contributeur
Soumis le : mercredi 20 octobre 2021 - 08:22:10
Dernière modification le : jeudi 21 octobre 2021 - 03:01:20

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Gérald Franz, Muhammad Hassan, Jamaluddin Abdullah, Chim Shen, Reza Mahmoodian, et al.. 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, MDPI, 2021, 5 (7), pp.189. ⟨10.3390/jcs5070189⟩. ⟨hal-03387802⟩

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