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Tool wear in ultrasonic vibration–assisted drilling of CFRP: a comparison with conventional drilling

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Abstract

Carbon fiber reinforced polymers (CFRPs) are becoming increasingly prevalent in the industries including automobile, aerospace, and military due to their light quality, high specific strength, high corrosion resistance, excellent thermodynamics performance, etc. However, these excellent properties easily result in intensive tool wear, short tool life, and reduced machining accuracy. Although ultrasonic vibration–assisted drilling (UVAD) was considered an effective drilling method to reduce tool wear, most reported studies focused on machining kinematics or mechanics, and very few studies systematically explored the tool wear behaviors in UVAD of CFRP. To fill this gap, this paper aims to investigate tool wear of high-speed steel (HSS) twist drill in UVAD of CFRP and compares these wear behaviors with those in conventional drilling based on the experimental observation of the worn drill morphologies. The effects of cutting parameters on tool wear were discussed with the special focus on the differences in tool wear between conventional drilling (CD) and UVAD. The observed wear behaviors can include abrasion, adhesion, oxidization, or the combination of them. The introduction of UVAD can effectively reduce the average width of tool flank wear with a maximum reduction of 13.0% when compared with CD. Both increased feed rate and decreased spindle speed can lead to decreased tool wear. The findings in this paper might offer guidance on the selection of cutting parameters for extending tool life in UVAD of CFRP.

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Availability of data and material

All data generated or analyzed during this study are included in this article and its additional files.

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Funding

The work described in this paper is supported by the Fundamental Research Funds for the Central Universities (Grant No: 2020-YB-025) and State Key Lab of Digital Manufacturing Equipment and Technology (Grant No: DMETKF2020026).

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Authors and Affiliations

  1. School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Wenjian Huang, Shiyu Cao, Qi Zhou, Chaoqun Wu & Kejia Zhuang

  2. School of Aerospace, University of Nottingham Ningbo China, Ningbo, 315100, China

    Hao Nan Li

  3. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, 430074, China

    Chaoqun Wu

  4. Hubei Key Laboratory of Advanced Technology for Automotive Components, Wuhan University of Technology, Wuhan, 430070, China

    Dahu Zhu

Authors
  1. Wenjian Huang
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Contributions

Wenjian Huang: writing-original draft preparation, methodology. Shiyu Cao: investigation, formal analysis, resources. Hao Nan Li: investigation, reviewing and editing. Qi Zhou: investigation, validation. Chaoqun Wu: reviewing and editing, funding acquisition, conceptualization, supervision. Dahu Zhu: investigation, data curation. Kejia Zhuang: reviewing and editing.

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Correspondence to Chaoqun Wu.

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Huang, W., Cao, S., Li, H.N. et al. Tool wear in ultrasonic vibration–assisted drilling of CFRP: a comparison with conventional drilling. Int J Adv Manuf Technol 115, 1809–1820 (2021). https://doi.org/10.1007/s00170-021-07198-w

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  • DOI: https://doi.org/10.1007/s00170-021-07198-w

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