UWE Bristol Engineering showcase 2015
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
Ali Albannai<br />
Beng Mechanical <strong>Engineering</strong><br />
The Tool Wear And Hole Quality Analysis on CFRP/Al<br />
Drilling<br />
1. Tools wear investigation using Scanning Electron<br />
Microscope (SEM)<br />
The investigation of the drill using a scanning electron microscope<br />
(SEM) before and after drilling clearly indicated tool wear on the drill<br />
.The drill tool wear could be attributed to the rise on temperature<br />
necessitated by the rubbing action of the fractured graphite fibers and<br />
the grains of solid carbide against the composite’s epoxy matrix.<br />
The results from SEM also reveal the formation of BUE and the<br />
dominant wear mechanism as indicated<br />
2. Holes quality<br />
Project Supervisor<br />
DR.marilyn Goh<br />
The surface quality of the holes was evaluated by taking a cross-section cut of the<br />
drilled holes. It was observed that the hole section lying in the Al plate had good<br />
surface finish as compared to that for the CFRP. This can be clearly seen in pictures.<br />
Though the holes circularity and the surface roughness were not quantified in this<br />
case, it is evident that there is a strong correlation between these parameters and tool<br />
wear.<br />
Project summary<br />
This project presents a study on the design and<br />
analysis of a cutter for drilling CFRP/Al stacked<br />
composite materials. Stacked plates of Carbon<br />
Fibre Reinforced Plastics/Aluminium (CFRP/Al) will<br />
be drilled using of solid carbide drill ZCC.CT<br />
1536SU05C-0600 KDG303 with a view to study the<br />
drilling process. The drilling tool modelled using<br />
SolidWorks.<br />
Project Objectives<br />
The main aim of this project is to study the wear of<br />
a carbide tool and hole quality by experimentally<br />
drilling through CFRP/Al stacked materials.<br />
•To test on different cutting speed and feed rates.<br />
•To analyse the stacked material wear using<br />
different cutting conditions.<br />
•To model and further explore and analyse the<br />
drilling process using a CAD software (SolidWorks).<br />
Project Conclusion<br />
This study has presented an extensive literature<br />
review on the drilling of CFRP/Al stack materials.<br />
CFRP/Al stack materials are usually used in<br />
aerospace applications besides other uses like in<br />
automotive and civil engineering applications. The<br />
optimization of the drilling conditions in these stack<br />
materials is of great economic considerations. Tool<br />
wear and the quality of the produced parts are key<br />
considerations to any optimization scheme. This<br />
report has presented a study on the tool wear and<br />
holes quality analysis when drilling CFRP/Al stacked<br />
composite materials. The drill that was used was<br />
the standard two flute drill, and the drilling and<br />
tool wear were investigated at a spindle speed of<br />
4000 rpm at a feed rate of 600 mm/min. These<br />
drilling conditions were found to be the most<br />
appropriate since they produced the smallest chips<br />
size. The chips size during drilling is an important<br />
parameter since it may have a bearing on holes<br />
quality, and hence the overall quality of the<br />
produced part.<br />
The study established that delamination is a major<br />
problem during the drilling of CFRP/Al stack<br />
materials. Delamination was found to be more at<br />
the hole exit as com-pared to the hole entry. The<br />
hole circularity and surface finish was found to be<br />
significantly affected by delamination.
Change language