Characterization and Effects of Fiber Pull-Outs in Hole Quality of Carbon Fiber Reinforced Plastics Composite
Abstract
:1. Introduction
2. Experimental Procedures
2.1. Drilling Experiments
2.2. Fiber Pull-Out Geometry Assessment
2.3. Hole Quality Assessment
3. Results and Discussion
3.1. Drilling Forces
3.2. Characterization of Fiber Pull-outs
3.3. Hole Size
3.4. Hole Roundness
3.5. Hole Surface Roughness
4. Conclusions
- (1)
- Both maximum thrust force and torque values increase as the feed increases due to the dependency of the drilling feed to the undeformed chip thickness. Due to matrix softening, maximum torque increases by decreasing the spindle speed condition.
- (2)
- An increase in the feed increased the fiber pull-out length. The maximum fiber pull-out depth, depending also on the drilling feed condition, ranged from 38–85 µm.
- (3)
- The hole size at lower feeds and higher speeds was found to be larger than the nominal drill diameter, which may be due to the instability and thermal expansion of the tool and the workpiece. Roundness of the holes on CFRP plates was found to be influenced by the feed rate change, rather than speed, which is a result of higher radial force in the feed increments.
- (4)
- The effect of fiber pull-outs is minimal to the hole size and roundness assessment results by the CMM. However, the precision-roundness machine is able to detect the fiber pull-out locations of a hole.
- (5)
- The surface roughness results as a factor of the feed rate during the process, increasing the roughness with both cutting speed and feed increments. Surface roughness parameter values measured by the surface profilometer are dependent more on the fiber pull-out length than the fiber pull-out depth.
Acknowledgments
Author Contributions
Conflicts of Interest
Appendix A
- α Fiber pull-out angle or:
- Fiber pull-out initiation angle or:
- B Projected length of fiber pull-out length on image
- C Projected distance of the fiber pull-out from center of hole
- α + Fiber pull-out completion angle
- R the radius of a hole.
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Diameter (mm) | Point Angle (°) | Helix Angle (°) | Flute Length (mm) |
---|---|---|---|
9.525 | 118 | 20 | 73 |
Run Numbers | Spindle Speed (RPM) | Feed (mm/rev) |
---|---|---|
1, 16 | 775 | 0.14 |
2, 3, 8, 9, 12, 14, 15, 18 | 3250 | 0.14 |
6, 17 | 5000 | 0.2 |
7, 22 | 3250 | 0.05 |
10, 23 | 5725 | 0.14 |
11, 21 | 1500 | 0.2 |
5, 20 | 5000 | 0.08 |
13, 24 | 3250 | 0.23 |
4, 19 | 1500 | 0.08 |
Spindle Speed (RPM) | 775 | 1500 | 3250 | 5000 | 5724 | |
---|---|---|---|---|---|---|
Feed (mm/rev) | 0.05 | 6.375 | ||||
0.08 | 5.918 | 5.740 | ||||
0.14 | 6.350 | 6.388 | 6.325 | |||
0.2 | 5.969 | 4.978 | ||||
0.23 | 6.909 |
Spindle Speed (RPM) | 775 | 1500 | 3250 | 5000 | 5724 | |
---|---|---|---|---|---|---|
Feed (mm/rev) | 0.05 | 2.538 20.985 | ||||
0.08 | 1.746 | 2.160 | ||||
14.49 | 17.056 | |||||
0.14 | 2.264 | 2.462 | 3.443 | |||
18.819 | 20.302 | 26.815 | ||||
0.2 | 2.254 | 2.943 | ||||
20.190 | 24.951 | |||||
0.23 | 2.571 | |||||
22.280 |
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Alizadeh Ashrafi, S.; Miller, P.W.; Wandro, K.M.; Kim, D. Characterization and Effects of Fiber Pull-Outs in Hole Quality of Carbon Fiber Reinforced Plastics Composite. Materials 2016, 9, 828. https://doi.org/10.3390/ma9100828
Alizadeh Ashrafi S, Miller PW, Wandro KM, Kim D. Characterization and Effects of Fiber Pull-Outs in Hole Quality of Carbon Fiber Reinforced Plastics Composite. Materials. 2016; 9(10):828. https://doi.org/10.3390/ma9100828
Chicago/Turabian StyleAlizadeh Ashrafi, Sina, Peter W. Miller, Kevin M. Wandro, and Dave Kim. 2016. "Characterization and Effects of Fiber Pull-Outs in Hole Quality of Carbon Fiber Reinforced Plastics Composite" Materials 9, no. 10: 828. https://doi.org/10.3390/ma9100828
APA StyleAlizadeh Ashrafi, S., Miller, P. W., Wandro, K. M., & Kim, D. (2016). Characterization and Effects of Fiber Pull-Outs in Hole Quality of Carbon Fiber Reinforced Plastics Composite. Materials, 9(10), 828. https://doi.org/10.3390/ma9100828