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Fiber pull-out damage formations and their effect on hole quality when drilling carbon fiber reinforced plastic (CFRP) composites using various tool geometries

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Abstract

This paper investigates how tool geometries and process conditions influence fiber pull-out formations, drilling forces, and hole quality parameters during the drilling process of quasi-isotropic CFRP laminates. The dry drilling experiments with the tools having three different point angles (two single point angles of 166° and 118°, and one double point angle of 100°/60°) were conducted with the feed conditions of 0.08 mm/rev to 0.2 mm/rev and the spindle speed conditions of 1500 rpm to 5000 rpm. A destructive method was used to quantify the fiber pull-out area and depth concerning the interaction angle of the cutting tool edge and fiber directions. The feed condition and the drill point angle affect the drilling forces and undeformed chip thickness, which influence the fiber pull-out formation mechanisms. The drill with the higher point angle produced less fiber pull-out area; however, it resulted in deeper fiber pull-outs, causing higher surface roughness.

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Acknowledgments

The authors disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: This work was supported by the Korea Institute of Industrial Technology (KITECH) in the Republic of Korea [grant number JE190014, entitled “Machining characteristics of environmental-friendly carbon fiber reinforced thermoplastics composites”] and the Ministry of Trade, Industry & Energy (MOTIE, Korea) [grant number 20018553, entitled “Development of preform manufacturing work-cell for a high productivity and high quality RTM (resin transfer molding) process”].

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Authors and Affiliations

  1. School of Engineering and Computer Science, Washington State University, Vancouver, WA, USA

    Dave Kim

  2. Nelson Global Products, Inc., Stoughton, WI, USA

    Sina Alizadeh Ashrafi

  3. Korea Institute of Industrial Technology (KITECH), Cheonansi, Korea

    Kangwoo Shin & Tae-Gon Kim

Authors
  1. Dave Kim
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  2. Sina Alizadeh Ashrafi
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  4. Tae-Gon Kim
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Correspondence to Tae-Gon Kim.

Additional information

Dave Kim is Professor and Mechanical Engineering Program Coordinator in the School of Engineering and Computer Science at Washington State University, Vancouver, WA, USA. His teaching and research interests have been in the areas of aerospace/space composites, fatigue enhancement, and advanced manufacturing processes. He has a long-standing involvement in research on the machining of advanced composite materials. His recent research efforts have also included fatigue strength improvement of aerospace structures and technical writing, focusing on the writing transfer of engineering undergraduates. He has authored over 180 peer-reviewed papers in these areas.

Sina Alizadeh Ashrafi is the Director of Business Strategy & Integration at Nelson Global Products, Inc. in Stoughton, WI, USA. He received his B.S. in Mechanical Engineering-Manufacturing and Production at Azad University of Tabriz in Iran, M.S. in Advanced Manufacturing Technology at Universiti Technologi in Malaysia, M.S. in Mechanical Engineering at Washington State University, Vancouver, WA, USA. His research has been related to the drilling of CFRP composites and their stacks with aluminum and tool wear of coated carbide tools in turning aluminum and hardened tool steels.

Kangwoo Shin is a technician at the Smart Manufacturing System Research Department, Korea Institute of Industrial Technology (KITECH). He received his master’s degree in materials engineering from Chonbuk National University in 2014. His research interests include studying the machining mechanisms, machining defects analysis, and tool wear in difficult-to-machine materials such as CFRP, titanium, and inconel718.

Tae-Gon Kim is a Principal Researcher at KITECH (Korea Institute of Industrial Technology), South Korea. He received his Ph.D. in Mechanical Engineering from Yonsei University, Korea. His research interests focus on machine tools, cutting tools, robotic machining, and machining processes for advanced materials such as CFRP, titanium, and nickel-based alloys.

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Kim, D., Ashrafi, S.A., Shin, K. et al. Fiber pull-out damage formations and their effect on hole quality when drilling carbon fiber reinforced plastic (CFRP) composites using various tool geometries. J Mech Sci Technol 37, 4271–4280 (2023). https://doi.org/10.1007/s12206-023-0743-8

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  • DOI: https://doi.org/10.1007/s12206-023-0743-8

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