Holistic review of drilling on CFRP composites: Techniques, FEM, sustainability, challenges, and advances

• Published in: International journal of advanced manufacturing technology Vol. 135; no. 5-6; pp. 2661 - 2696
• Main Authors: Hamed, Muhammad, Zhang, Chen, Khan, Aqib Mashood, Saleem, Muhammad, Musanur, M. D.
• Format: Journal Article
• Language: English
• Published: London Springer London 01-11-2024; Springer Nature B.V
• Subjects: Aerospace engineering; Air cooling; Anisotropy; CAE) and Design; Carbon fiber reinforced plastics; Composite materials; Compressed air; Computer-Aided Engineering (CAD; Corrosion resistance; Cryogenic cooling; Cutting force; Damage; Deburring; Drilling; Energy consumption; Engineering; Feed rate; Fiber reinforced polymers; Finite element method; Heterogeneity; Industrial and Production Engineering; Mechanical Engineering; Media Management; Optimization; Original Article; Parameters; Strength to weight ratio; Sustainability; Thermal resistance; Thermal stability; Thrust; Tool wear; Torque; Drilling; Cutting parameters; Sustainability; CFRP; Hole quality and surface roughness; Finite element modeling (FEM)
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-024-14317-w

Carbon fiber-reinforced polymer Please check Affiliations if captured/presented correctly.(CFRP) composites are essential in aerospace, automotive, and civil engineering due to their strength-to-weight ratio, stiffness, thermal stability, and corrosion resistance. However, drilling CFRPs is challenging due to anisotropy, heterogeneity, and sensitivity to cutting forces, often causing delamination, burr formation, tearing surface ca[vities, and roughness. This review examines advancements in drilling techniques, analyzing their mechanisms, benefits, and limitations to improve hole quality and minimize damage. Finite element modeling (FEM) plays a crucial role in optimizing drilling by predicting thrust forces, torques, and damage, with recent advancements enhancing damage reduction. The review explores the influence of drilling parameters on thrust force, torque, temperature, and various damage types in CFRP composites. This review proposes strategies to optimize these parameters, including tool geometries, deburring techniques, pilot holes, and variable feed rates, while emphasizing sustainability for environmental and efficiency benefits. It analyzes research shortcomings, outlines future directions, and focuses on sustainable methods like cryogenic cooling, MQL, and compressed air cooling to reduce energy use, tool wear, and emissions. Future research should reveal the mapping mechanism between these parameters and CFRP hole-making quality, proposing an optimized, sustainable drilling strategy to reduce defects and improve hole quality.
Graphical Abstract