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IMECE2014
November 14-20, 2014, Montreal, Quebec, Canada
IMECE2014-37046
Study of Cutting Speed Variation in the Ultrasonic Assisted Drilling of Carbon
Fibre Composites
Aniruddha Gupta
WMG, University of Warwick
Coventry, West Midlands, UK
Iain McEwen
School of Engineering,
University of Warwick
Coventry, West Midlands, UK
Stuart Barnes
WMG, University of Warwick
Coventry, West Midlands, UK
Nadia Kourra
WMG, University of Warwick
Coventry, West Midlands, UK
ABSTRACT
Ultrasonic assisted drilling (UAD) has been proven
effective for the thrust force reduction as compared to
conventional drilling (CD) for same machining parameters. The
following research was focused on the examination of exit
delamination, machined surface and cutting temperature
measurement in UAD and a comparison to that in CD at the
cutting speeds of 0.942 m/min, 9.42 m/min, 94.2 m/min and
282.6 m/min at a constant feed rate of 0.05 mm/rev in the
through-hole drilling of CFRP material. X-Ray computed
tomography (CT) was used to identify the exit delamination,
internal damage, circularity and center deviation in CD and
UAD. A maximum of 82.8% reduction in the center deviation
and 33.2% reduction in circularity of the holes were found
when drilled in UAD as compared to those in CD. Furthermore,
the cutting temperature in the drilling of CFRP has been
measured and compared for both the cases of CD and UAD.
Ultrasonic assistance produced 10C higher cutting temperature
than that in CD at the cutting speed of 282.6 m/min while at
lower cutting speeds (0.942 m/min and 9.42 m/min), the cutting
temperatures with and without ultrasonic assistance did not
have a significant difference (2C and 4C respectively).
1. INTRODUCTION
Carbon fibre reinforced plastics (CFRPs) are attractive as
aircraft and aerospace structural components due to their lighter
weight and higher specific strength as compared to metals [17] which has led to greater weight savings resulting in greater
pay load, longer range and fuel saving in comparison to the
metals [8]. In spite of curing to the final shape, the machining
of composites is required at several stages of the production
e.g. cutting and drilling of holes. The mechanical drilling
Mark A. Williams
WMG, University of Warwick
Coventry, West Midlands, UK
rc
ri i
(2)
= 2
(3)
(4)
(5)
XD = tan1 ( tan )
(6)
tan
cos
(7)
sin
tan
Where, tan =
+ tan
cos
; tan =
tan
cos
= sin1 ( )
Putting
the
respective
values
from
tan[tan
( tan )+ tan
)]+ tan
cos
sin
(8)
Hence, the effective normal rake angle in UAD [19]
tan
tan
cos
(9)
60
r = 1.0 mm UAD
r = 1.4 mm UAD
40
r = 1.8 mm UAD
r = 2.2 mm UAD
20
r = 2.6 mm UAD
r = 3.0 mm UAD
0
0
20
40
60
80
-20
r = 1.0 mm CD
r = 1.4 mm CD
r = 1.8 mm CD
r = 2.2 mm CD
-40
r = 2.6 mm CD
r = 3.0 mm CD
-60
Time (micro seconds)
60
r = 1.0 mm UAD
r = 1.4 mm UAD
40
r = 1.8 mm UAD
r = 2.2 mm UAD
20
r = 2.6 mm UAD
r = 3.0 mm UAD
0
0
20
40
60
80
-20
r = 1.0 mm CD
r = 1.4 mm CD
r = 1.8 mm CD
r = 2.2 mm CD
-40
r = 2.6 mm CD
r = 3.0 mm CD
-60
Time (micro seconds)
50
40
r = 1.0 mm UAD
r = 1.4 mm UAD
30
r = 1.8 mm UAD
r = 2.2 mm UAD
20
r = 2.6 mm UAD
10
r = 3.0 mm UAD
r = 1.0 mm CD
r = 1.4 mm CD
20
40
60
80
-10
r = 1.8 mm CD
r = 2.2 mm CD
r = 2.6 mm CD
-20
r = 3.0 mm CD
-30
30
r = 1.0 mm UAD
r = 1.4 mm UAD
25
r = 1.8 mm UAD
r = 2.2 mm UAD
20
r = 2.6 mm UAD
r = 3.0 mm UAD
15
r = 1.0 mm CD
r = 1.4 mm CD
10
r = 1.8 mm CD
r = 2.2 mm CD
r = 2.6 mm CD
r = 3.0 mm CD
0
0
20
40
60
80
CD
Ultrasonic actuator
CFRP strip
250
Drill
Dynamometer
UAD
Fixture
230
210
190
170
150
50
100
150
200
250
300
Figure 4: Thrust force profile during the drilling of one hole (0.942
m/min, 0.05 mm/rev), average thrust force = 231.8 N
Figure 6: (a) Straight machined marks and the drilled hole, (b)
center identification and the dimensions of hole and marks in mm.
Delamination factor
CD
1.3
1.25
UAD
1.2
1.15
1.1
1.05
1
0
50
100
150
200
Cutting speed (m/min)
250
300
1.35
3.12
3.11
3.1
3.09
3.08
CD
3.07
UAD
3.06
3.05
0
50
100
150
200
Cutting speed (m/min)
250
300
4.2.3. Circularity
The circularity of each hole was calculated from the
difference between the maximum and the minimum radius in a
particular layer including the damage of the layer. The average
of the circularity of all the layers between the drilled depths
from 2 mm to 5 mm was considered as the average circularity
of a hole. The lower is the circularity value, the more circular
the hole is and the less damage has been produced. The
circularity values for the various cutting speeds have been
plotted in the Figure 9. It was found that the average circularity
values were lower in the case of UAD as compared to those in
CD at all the parameters except 9.42 m/min cutting speed. At
9.42 m/min cutting speed the circularity was found to be lower
in CD than that in UAD. Also, at 282.6 m/min, the average
circularity for CD was found to be the highest amongst all the
cutting speeds which also corresponds to the highest average
maximum radius of the internal damage at 282.6 m/min cutting
speed as shown in the Figure 8.
0.25
0.2
0.15
0.1
0.08
0.07
0.06
0.05
CD
0.04
UAD
0.03
0.02
0.01
0
0
CD
0.05
50
100
150
200
Cutting speed (m/min)
250
300
UAD
0
0
50
100
150
200
Cutting speed (m/min)
250
300
Surface mount
thermocouple
1 mm
setup
CFRP Plates
for
cutting
temperature
9.42, 126.56
120
Temperature (C)
UAD
9.42, 122.59
100
94.2, 90.39
282.6, 81.66
80
0.942, 64.61
60
0.942, 62.54
94.2, 70.25
282.6, 70.76
40
20
0
0
50
100
150
200
Cutting Speed (m/min)
250
300
10
[11]
[12]
[13]
[14]
[15]
[16]
[17]
[18]
[19]
[20]
8. REFERENCES
[1]
[2]
[3]
[4]
[5]
[6]
[7]
[8]
[9]
[10]
[21]
[22]
[23]
[24]
[25]
[26]
[27]
11