Enhancing dimensional accuracy of the produced holes in CFRP by ultrasonic vibration assistance

Document Type : Original Article

Authors

Assistant Professor, Department of Mechanical Engineering, Arak University of Technology, Arak, Iran

Abstract

Carbon fiber reinforced composites have many industrial applications due to their suitable mechanical and physical properties. Drilling is one of the common methods for creating connections between fiber-reinforced structures. Rotary ultrasonic drilling process is one of the new methods in machining fiber-reinforced composites, which has been highly regarded in recent years. Exact dimensional tolerance is one of the important issues in machining of carbon fiber reinforced composites. Therefore, in recent years, new tools such as cored diamond tools are used in drilling fiber-reinforced composites, considering force reduction and simultaneous drilling and grinding inside the hole. In this research, the dimensional accuracy in the drilling process using ultrasonic waves in carbon fibers reinforced composites has been investigated. The results indicate the effective axial force reduction in vibration drilling compared to traditional drilling. Besides, the results show that the cylindrical and roundness tolerance have been improved significantly while using ultrasonic vibrations. According to the examinations, it was observed that the tool rotational speed increasing and feed rate decreasing improve quality of the hole.

Keywords

References

[1] Chern G-L, Lee H-J. Using workpiece vibration cutting for micro-drilling. The International Journal of Advanced Manufacturing Technology: 2006;27:688-92. doi: 10.1007/s00170-004-2255-8
[2] Chang SS, Bone GM. Burr height model for vibration assisted drilling of aluminum 6061-T6. Precision Engineering: 2010;34(3):369-75. doi: 10.1016/j.precisioneng.2009.09.002
[3] Neugebauer R, Stoll A. Ultrasonic application in drilling. Journal of materials processing technology: 2004;149(1-3):633-9. doi: 10.1016/j.jmatprotec.2003.10.062
[4] Liu D, Tang Y, Cong W. A review of mechanical drilling for composite laminates. Composite structures: 2012;94(4):1265-79. doi: 10.1016/j.compstruct.2011.11.024
[5] Arul S, Vijayaraghavan L, Malhotra S, Krishnamurthy R. The effect of vibratory drilling on hole quality in polymeric composites. International Journal of Machine Tools and Manufacture: 2006;46(3-4):252-9. doi: 10.1016/j.ijmachtools.2005.05.023
[6] Wang X, Wang L, Tao J. Investigation on thrust in vibration drilling of fiber-reinforced plastics. Journal of Materials Processing Technology: 2004;148(2):239-44. doi: 10.1016/j.jmatprotec.2003.12.019
[7] Phadnis VA, Makhdum F, Roy A, Silberschmidt VV. Experimental and numerical investigations in conventional and ultrasonically assisted drilling of CFRP laminate. Procedia Cirp: 2012;1:455-9. doi: 10.1016/j.procir.2012.04.081
[8] Hocheng H, Tsao C. Effects of special drill bits on drilling-induced delamination of composite materials. International Journal of Machine Tools and Manufacture: 2006;46(12-13):1403-16. doi: 10.1016/j.ijmachtools.2005.10.004
[9] Liu J, Zhang D, Qin L, Yan L. Feasibility study of the rotary ultrasonic elliptical machining of carbon fiber reinforced plastics (CFRP). International Journal of Machine Tools and Manufacture: 2012;53(1):141-50. doi: 10.1016/j.ijmachtools.2011.10.007
[10] Amin S, Ahmed M, Youssef H. Computer-aided design of acoustic horns for ultrasonic machining using finite-element analysis. Journal of Materials Processing Technology: 1995;55(3-4):254-60. doi: 10.1016/0924-0136(95)02015-2
[11] Banerjee B, Pradhan S, Das S, Chakraborty A, Dhupal D. Horn design and analysis in ultrasonic machining process using ANSYS. Advances in Materials and Processing Technologies: 2022;8(sup3):1359-72. doi: 10.1080/2374068X.2021.1945266
[12] Singh DP, Mishra S, Porwal RK. Modal analysis of ultrasonic horn using finite element method. Materials Today: Proceedings: 2019;18:3617-23. doi: 10.1016/j.matpr.2019.07.293
[13] Amini S, Baraheni M, Mardiha A. Parametric investigation of rotary ultrasonic drilling of carbon fiber reinforced plastics. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering: 2018;232(5):540-54. doi: 10.1177/0954408917727199
[14] Abdelkawy A, El-Hofy H. Experimental and statistical study for measurements of surface roughness and hole geometry of ultrasonic-assisted drilling of soda glass. Journal of the Brazilian Society of Mechanical Sciences and Engineering: 2021;43:1-11. doi: 10.1007/s40430-021-03172-5
[15] Baraheni M, Tabatabaeian A, Amini S, Ghasemi AR. Parametric analysis of delamination in GFRP composite profiles by performing rotary ultrasonic drilling approach: Experimental and statistical study. Composites Part B: Engineering: 2019;172:612-20. doi: 10.1016/j.compositesb.2019.05.057
[16] Amini S, Baraheni M, Moeini Afzal M. Statistical study of the effect of various machining parameters on delamination in drilling of carbon fiber reinforced composites. Journal of science and technology of composites: 2018;5(1):41-50. doi: 10.22068/JSTC.2018.28562
[17] Wang J, Zha H, Feng P, Zhang J. On the mechanism of edge chipping reduction in rotary ultrasonic drilling: a novel experimental method. Precision Engineering: 2016;44:231-5. doi: 10.1016/j.precisioneng.2015.12.008
[18] Baraheni M, Amini S. Feasibility study of delamination in rotary ultrasonic-assisted drilling of glass fiber reinforced plastics. Journal of Reinforced Plastics and Composites: 2018;37(1):3-12. doi: 10.1177/0731684417729565
Iranian Journal of Manufacturing Engineering
Volume 10, Issue 3 - Serial Number 65
Best Paper of ICME 2022
May 2023
Pages 1-8

Files

Share

How to cite

Statistics