A comparative study on tool wear and laminate damage in drilling of carbon-fiber reinforced polymers (CFRP)
Preliminary to successful assembling, drilling of composites like carbon-fiber reinforced polymers (CFRP) is an important but difficult process. The anisotropic and heterogeneous structure of the laminates and the highly abrasive nature of the carbon fibers make it prone to critical damages in the w...
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| Published in: | Composite structures Vol. 155; pp. 173 - 183 |
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| Main Authors: | , , , , , , , , |
| Format: | Journal Article |
| Language: | English |
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Elsevier Ltd
01-11-2016
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| Abstract | Preliminary to successful assembling, drilling of composites like carbon-fiber reinforced polymers (CFRP) is an important but difficult process. The anisotropic and heterogeneous structure of the laminates and the highly abrasive nature of the carbon fibers make it prone to critical damages in the workpiece as well as extensive tool wear. In this work, drill series with uncoated and diamond coated tungsten carbide hard metal tools were performed in two CFRP laminates with significant differences in their microstructure. The tool wear behavior and the corresponding workpiece damage were intensively studied to figure out the correlations between wear and delamination damage. Therefore, novel and well established methods in tool wear analysis and delamination assessment based on light optical microscopy were applied and critically evaluated.
The abrasive tool wear on uncoated carbide drill can be well described by the cutting edge rounding (CER) allowing strong correlations with the inflicted workpiece damage, whereas for coated tools measuring CER is not an appropriate method. The machinability of CFRP was found to be highly influenced by the presence of residual porosity in the composite laminate. Hence, the benefit in lifetime of the diamond coating can only be utilized in machining of high quality laminates. |
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| AbstractList | Preliminary to successful assembling, drilling of composites like carbon-fiber reinforced polymers (CFRP) is an important but difficult process. The anisotropic and heterogeneous structure of the laminates and the highly abrasive nature of the carbon fibers make it prone to critical damages in the workpiece as well as extensive tool wear. In this work, drill series with uncoated and diamond coated tungsten carbide hard metal tools were performed in two CFRP laminates with significant differences in their microstructure. The tool wear behavior and the corresponding workpiece damage were intensively studied to figure out the correlations between wear and delamination damage. Therefore, novel and well established methods in tool wear analysis and delamination assessment based on light optical microscopy were applied and critically evaluated.
The abrasive tool wear on uncoated carbide drill can be well described by the cutting edge rounding (CER) allowing strong correlations with the inflicted workpiece damage, whereas for coated tools measuring CER is not an appropriate method. The machinability of CFRP was found to be highly influenced by the presence of residual porosity in the composite laminate. Hence, the benefit in lifetime of the diamond coating can only be utilized in machining of high quality laminates. Preliminary to successful assembling, drilling of composites like carbon-fiber reinforced polymers (CFRP) is an important but difficult process. The anisotropic and heterogeneous structure of the laminates and the highly abrasive nature of the carbon fibers make it prone to critical damages in the workpiece as well as extensive tool wear. In this work, drill series with uncoated and diamond coated tungsten carbide hard metal tools were performed in two CFRP laminates with significant differences in their microstructure. The tool wear behavior and the corresponding workpiece damage were intensively studied to figure out the correlations between wear and delamination damage. Therefore, novel and well established methods in tool wear analysis and delamination assessment based on light optical microscopy were applied and critically evaluated. The abrasive tool wear on uncoated carbide drill can be well described by the cutting edge rounding (CER) allowing strong correlations with the inflicted workpiece damage, whereas for coated tools measuring CER is not an appropriate method. The machinability of CFRP was found to be highly influenced by the presence of residual porosity in the composite laminate. Hence, the benefit in lifetime of the diamond coating can only be utilized in machining of high quality laminates. |
| Author | Lissek, Fabian Kaufeld, Michael Haeger, Andreas Sripathy, Prithvi Bernthaler, Timo Gaugel, Simon Schneider, Gerhard Meinhard, Dieter Knoblauch, Volker |
| Author_xml | – sequence: 1 givenname: Simon surname: Gaugel fullname: Gaugel, Simon organization: Aalen University of Applied Sciences, Materials Research Institute, Aalen, Germany – sequence: 2 givenname: Prithvi surname: Sripathy fullname: Sripathy, Prithvi organization: Aalen University of Applied Sciences, Materials Research Institute, Aalen, Germany – sequence: 3 givenname: Andreas surname: Haeger fullname: Haeger, Andreas organization: Aalen University of Applied Sciences, Materials Research Institute, Aalen, Germany – sequence: 4 givenname: Dieter surname: Meinhard fullname: Meinhard, Dieter organization: Aalen University of Applied Sciences, Materials Research Institute, Aalen, Germany – sequence: 5 givenname: Timo surname: Bernthaler fullname: Bernthaler, Timo organization: Aalen University of Applied Sciences, Materials Research Institute, Aalen, Germany – sequence: 6 givenname: Fabian surname: Lissek fullname: Lissek, Fabian organization: Ulm University of Applied Sciences, Institute of Production Engineering and Materials Testing, Ulm, Germany – sequence: 7 givenname: Michael surname: Kaufeld fullname: Kaufeld, Michael organization: Ulm University of Applied Sciences, Institute of Production Engineering and Materials Testing, Ulm, Germany – sequence: 8 givenname: Volker surname: Knoblauch fullname: Knoblauch, Volker email: volker.knoblauch@hs-aalen.de organization: Aalen University of Applied Sciences, Materials Research Institute, Aalen, Germany – sequence: 9 givenname: Gerhard surname: Schneider fullname: Schneider, Gerhard organization: Aalen University of Applied Sciences, Materials Research Institute, Aalen, Germany |
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| SubjectTerms | Abrasive wear Carbide tool Carbon fiber reinforced plastics CFRP Correlation analysis Damage Delamination Diamond coating Drilling Laminates Tool wear Workpieces |
| Title | A comparative study on tool wear and laminate damage in drilling of carbon-fiber reinforced polymers (CFRP) |
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