Analysis of drilling performance of carbon fiber reinforced polymer with special tool geometries and Raman spectrums

Hybrid Advances Pub Date : 2025-03-21 DOI:10.1016/j.hybadv.2025.100455

Rishikesan Visuvamithiran , Arunachalam Narayanaperumal , Velmurugan Ramachandran , Vijayaraghavan Lakshmanan

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Abstract

Carbon fiber reinforced polymer (CFRP) composite is an advanced material used in different industrial domains due to its improved strength-to-weight ratio and high flexural strength. Drilling operations are one of the most inevitable manufacturing processes for fabricating CFRP components. However, drilling CFRP composites often induces critical damage in the vicinity of the drilled holes owing to its anisotropic nature, high brittleness, and other physical properties. Hence, a thorough understanding of material removal mechanisms and selection of proper drill tools with optimized tool geometry is indeed a prior necessity to drill high-quality holes with minimal defects in CFRP composites.

In this work, an attempt is made to investigate the influence of drill tool point angle on the drilling mechanism and drilled hole quality in CFRP composites. Drills with different point angles such as 90°, 118° and 135° are examined under various drilling settings. Thrust force is employed to analyse the dynamics of the drilling process and material removal mechanism. Residual stresses induced during the drilling operation are examined in detail using micro-Raman spectroscopy analysis. Experimental results show that reducing the point angle to 90° significantly improved drilling performance in CFRP composites compared to the standard 118° drill. At higher feed rates (0.06–0.16 mm/rev), the PA90 tool caused 11.5 % and 17 % less damage than the PA118 and PA135 tools, respectively. The 90° tool also produced fewer residual stresses, as indicated by Raman band shifts. Thus, the 90° point angle tool is suitable for high-speed machining. The point angle is a critical parameter and its impact on damage induction and the quality of the drilled CFRP is demonstrated in detail.

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基于特殊刀具几何形状和拉曼光谱的碳纤维增强聚合物钻井性能分析

碳纤维增强聚合物（CFRP）复合材料因其提高了强度重量比和较高的抗弯强度而被广泛应用于不同的工业领域。钻削作业是CFRP构件制造过程中最不可避免的工序之一。然而，由于CFRP复合材料的各向异性、高脆性和其他物理特性，在钻孔附近往往会引起临界损伤。因此，要想在CFRP复合材料中钻出缺陷最小的高质量孔，首先必须彻底了解材料去除机制，并选择具有优化刀具几何形状的合适钻孔工具。本文尝试研究了钻头刀尖角度对CFRP复合材料钻孔机理和钻孔质量的影响。在不同的钻井设置下，测试了不同角度的钻头，如90°、118°和135°。利用推力分析了钻孔过程动力学和材料去除机理。利用微拉曼光谱分析技术对钻井过程中产生的残余应力进行了详细研究。实验结果表明，与标准的118°钻头相比，将尖角减小到90°可显著提高CFRP复合材料的钻进性能。在较高的进给速率下（0.06-0.16 mm/rev）， PA90刀具造成的损伤比PA118和PA135刀具分别减少11.5%和17%。正如拉曼带位移所表明的那样，90°刀具产生的残余应力也更少。因此，90°角刀具适合高速加工。本文详细论述了点角对CFRP钻孔损伤诱导和质量的影响。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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Hybrid Advances

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