Hole-making and drilling technology for composites: advantages, limitations and potential

Front Cover......Page 1
Hole-Making and Drilling Technology for Composites: Advantages, Limitations and Potential......Page 4
Copyright......Page 5
Contents......Page 6
List of contributors......Page 10
 1.2  Hole-making for composite laminates......Page 12
   1.2.1.1  Conventional drilling......Page 13
   1.2.1.3  Grinding drilling......Page 14
   1.2.1.4  Vibration-assisted twist drilling......Page 15
   1.2.1.5  Orbital drilling......Page 16
   1.2.1.6  Milling......Page 17
   1.2.2.1  Abrasive water jet machining......Page 18
   1.2.2.2  Electro-discharge machining......Page 20
  1.2.3  Nonmachining methods......Page 21
 1.3  Conclusions......Page 22
 References......Page 23
 2.2  Delamination......Page 28
 2.3  Delamination mechanism......Page 29
 2.4  Causes of delamination......Page 30
 2.5  Delamination measurement......Page 35
 2.6  Conclusions......Page 38
 References......Page 39
 Further reading......Page 41
 3.1  Introduction......Page 42
  3.2.1  Mechanical joints......Page 43
  3.2.2  Adhesive joints......Page 44
 3.3  Standard test procedure......Page 45
  3.3.1  Bearing test......Page 46
   3.3.1.1  Procedure A......Page 47
   3.3.1.3  Procedure C......Page 48
   3.3.1.4  Procedure D......Page 49
  3.3.2  Open hole and filled hole test......Page 50
  3.3.3  Pull-through test......Page 51
  3.3.4  Pin-bearing strength test......Page 52
 3.5  Conclusions......Page 53
 References......Page 54
 Further reading......Page 57
 4.1  Introduction......Page 58
  4.2.1  CFRC and glass fiber reinforced composite (GFRC) laminates......Page 59
  4.2.2  Fiber metal composite (FMC) laminates......Page 60
 4.3  Hole-making procedures in drilling FRC laminate materials......Page 61
  4.3.1  Predrilling process (stage 1)......Page 62
  4.4.1  Drill tool material......Page 63
   4.4.1.3  Ceramic/zirconia......Page 65
  4.4.2  Drill tool design......Page 67
  4.5.1  Occurence of delamination (fiber pull-out and push-out)......Page 68
  4.5.2  Hole surface roughness......Page 69
 4.6  Summary......Page 70
 References......Page 71
 5.1  Introduction......Page 74
  5.2.1  Fabrication of laminates......Page 75
  5.2.2  Drilling test details......Page 76
  5.2.3  Measurements......Page 77
  5.3.1  Analysis of chip formation......Page 78
  5.3.2  Analysis of force signals......Page 79
  5.3.3  Analysis of drilling-inducedforces......Page 80
  5.3.4  Analysis of drilling-induced damages......Page 83
 5.4  Conclusions......Page 85
 References......Page 86
 6.1  Introduction......Page 88
 6.2  Ultrasonic machining: Process principle......Page 90
  6.3.2  Experimental setup......Page 91
 6.4  Results and discussion......Page 92
 6.5  Conclusions......Page 95
 References......Page 97
 7.1  Introduction......Page 100
  7.2.1  Laser percussion drilling......Page 101
  7.2.2  Laser trepanning drilling......Page 102
 7.4  Laser drilling methods to suppress delamination and thermal defects in composites......Page 103
  7.5.1  Nanosecond laser pulses......Page 105
  7.5.2  Picosecond laser pulses......Page 106
  7.5.3  Femtosecond laser pulses......Page 107
 Acknowledgment......Page 108
 References......Page 109
 8.1  Introduction......Page 112
 8.3  Finite element study......Page 114
  8.3.3  Solver methodology......Page 116
 8.5  Conclusions......Page 118
 References......Page 124
 9.1  Introduction......Page 126
  9.3.1  Studied parameters......Page 127
   9.3.1.2  Puncher profile......Page 128
   9.3.3.2  Shearing edge......Page 131
   9.3.3.3  Burr......Page 132
   9.4.1.1  Top and bottom diameter......Page 133
  9.4.2  Effect of puncher profile......Page 136
   9.4.2.1  Top and bottom diameter......Page 137
   9.4.2.2  Complete shearing......Page 138
  9.4.3  Modification of the punching mechanism......Page 139
 9.5  Conclusion......Page 142
 References......Page 143
 10.1  Introduction......Page 146
 10.3  Hole quality issues in single-shot drilling process of stacked material......Page 147
  10.3.2  Hole surface roughness......Page 148
  10.3.3  Burr height formation at exit hole......Page 152
 10.4  Benefits and limitations of single-shot drilling process......Page 153
 10.5  Tool strategies for drilling of stacked material......Page 154
  10.5.2  Polycrystalline diamond application......Page 155
  10.5.3  Customization drill geometry......Page 156
 References......Page 157
 11.1  Introduction......Page 160
 11.2  Sustainability issues......Page 161
  11.2.2  Machining performance improvement......Page 162
  11.2.3  Waste management system......Page 163
 11.3  Conclusions and challenges in hole-making technologies......Page 166
 References......Page 168
 12.1  Introduction......Page 172
 12.2  Effects of machining on composites......Page 173
 12.3  Fabrication of composites......Page 175
 12.4  Mathematical formulation......Page 177
 12.5  Thrust force......Page 178
 12.6  Analysis of variance......Page 180
 12.7  Thrust force for various cutting velocities and feed rates......Page 182
 12.8  Regression analysis......Page 186
  12.8.2  Delamination factor......Page 187
  12.9.2  Delamination factor of the holes drilled using HSS drill tool......Page 189
 12.10  Conclusion......Page 190
 Further reading......Page 191
 13.1  Introduction......Page 192
 13.2  Methodology......Page 193
  13.2.1  Preparation of the composite panel......Page 194
 13.3  Results and discussion......Page 195
  13.3.1  Punching load......Page 197
  13.3.2  Burr height......Page 198
 13.4  Conclusions and recommendations for future work......Page 201
 References......Page 202
 14.1  Introduction......Page 204
 14.2  Scheme of experiments......Page 205
  14.3.1  Experimental procedure......Page 206
   14.3.2.1  Effect on tool wear rate......Page 207
   14.3.2.2  Effect on surface roughness......Page 209
  14.4.2  Response surface methodology......Page 213
  14.4.4  Design matrix and experimental details......Page 215
  14.4.6  Optimization of process parameters......Page 218
 14.5  Conclusions......Page 219
 References......Page 220
 15.1  Introduction......Page 222
  15.2.2  Hole neatness......Page 223
  15.2.3  Delamination factor......Page 224
 15.3  Performance......Page 225
   15.4.2.1  Method 1: Drilling......Page 226
   15.4.2.2  Method 2: Punching......Page 227
  15.4.4  Specimen analysis......Page 228
 15.5  Result and discussion......Page 229
 Acknowledgment......Page 235
 References......Page 236
 Further reading......Page 237
Index......Page 238
Back Cover......Page 246