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Proposal of a tilted helical milling technique for high-quality hole drilling of CFRP: analysis of hole surface finish

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Abstract

An innovative machining process, i.e., tilted helical milling (THM), was proposed previously by the authors for high-quality hole drilling of CFRP as an alternative technique to conventional helical milling (CHM). To further develop the THM technique, hole surface finish with THM is analyzed and compared to that finished with CHM in this article. Theoretical analysis results show that a large amount of fiber bending and fiber-matrix debinding in CHM will occur in the hole surface when instantaneous fiber cutting angle α lies in the range of 90° to 180° due to the tool pushing. This phenomenon can be mitigated in THM owing to a downward cutting force component along the hole axis, which makes fibers fracture easily. The theoretical analysis results are confirmed by CT scans and SEM results of surface morphology of holes, indicating THM is useful for obtaining high-quality hole surface finish. In addition, compared with CHM, damage generation, such as entrance split and exit delamination of the hole, can be restrained with THM technique.

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Acknowledgements

Deepest thanks is given to Mr. Junfei Huang (Shimadzu (China) Co., LTD. Shenzhen Branch) for his help on the experimental works of CT-scans.

Funding

The authors received financial support from the National Natural Science Foundation of China (Grant nos. 51405218, 51505444) and Shenzhen knowledge innovation plan (Grant no. J20180097).

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Authors and Affiliations

  1. Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen, 518055, Guangdong, China

    Qiang Wang, Yongbo Wu & Dong Lu

  2. School of Power and Mechanical Engineering, Wuhan University, Wuhan, Hubei, 430072, China

    Qiang Wang

  3. School of Aeronautics and Manufacturing Engineering, Nanchang Hangkong University, Nanchang, 330063, Jiangxi, China

    Yongbo Wu & Dong Lu

  4. Fine Optical Engineering Research Center, Chengdu, 610041, China

    Yaguo Li

  5. Department of Machine Intelligence and Systems Engineering, Akita Prefectural University, Yurihonjo, Akita, 015-0055, Japan

    Teruo Bitoh

Authors
  1. Qiang Wang
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  2. Yongbo Wu
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  3. Yaguo Li
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  4. Dong Lu
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  5. Teruo Bitoh
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Corresponding authors

Correspondence to Yongbo Wu or Yaguo Li.

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Wang, Q., Wu, Y., Li, Y. et al. Proposal of a tilted helical milling technique for high-quality hole drilling of CFRP: analysis of hole surface finish. Int J Adv Manuf Technol 101, 1041–1049 (2019). https://doi.org/10.1007/s00170-018-2995-5

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  • DOI: https://doi.org/10.1007/s00170-018-2995-5

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