Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites
Carbon fiber-reinforced plastics (CFRPs) have been specially developed to enhance the performance of commercial and military aircraft because of their strength, high stiffness-to-density ratios, and superior physical properties. On the other hand, fasteners and joints of CFRP materials may be weak d...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-07-01
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| Series: | Micromachines |
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| Online Access: | https://www.mdpi.com/2072-666X/14/7/1427 |
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| author | Çağın Bolat Uçan Karakılınç Bekir Yalçın Yahya Öz Çağlar Yavaş Berkay Ergene Ali Ercetin Fatih Akkoyun |
| author_facet | Çağın Bolat Uçan Karakılınç Bekir Yalçın Yahya Öz Çağlar Yavaş Berkay Ergene Ali Ercetin Fatih Akkoyun |
| author_sort | Çağın Bolat |
| collection | DOAJ |
| description | Carbon fiber-reinforced plastics (CFRPs) have been specially developed to enhance the performance of commercial and military aircraft because of their strength, high stiffness-to-density ratios, and superior physical properties. On the other hand, fasteners and joints of CFRP materials may be weak due to occurring surface roughness and delamination problems during drilling operations. This study’s aim is to investigate the drilling characterization of CFRPs with different drilling parameters and cutting tools. Drilling tests were performed with the Taguchi orthogonal array design (L18: 2^1 3^3). Tests were conducted with three levels of cutting speed (15, 30, 45 m/min), three levels of feed rate (0.05, 0.1, 0.2 mm/rev), two levels of drill diameter (3 and 5 mm), and three different types of drills (two twist drills with a point angle of 138° and 120° and one brad drill). Thrust forces were recorded during drilling tests, and afterwards surface roughness and hole delamination were measured. Obtained results were analyzed with Taguchi and two-way ANOVA. The general tendency was that low cutting speed, high feed rate, and small diameter drill caused an increase in thrust force. Surface roughness decreases with increasing tool diameter, decreasing feed, and cutting speed. Delamination factors of the samples dropped depending on decreasing thrust force levels. Remarkably, it is possible to control the delamination factor values via better surface quality. The brad drill and larger point angle have a negative effect on the drilling quality of CFRPs. According to all results, the cutting speed of 45 m/min and feed rate of 0.05 mm/rev using a type II drill having a 120° point angle and 5 mm diameter (12th trial) and the cutting speed of 30 m/min and feed rate of 0.05 mm/rev using a type II drill having a 120° point angle and 3 mm diameter (2nd trial) were determined as optimum drilling conditions. |
| first_indexed | 2024-03-11T00:49:05Z |
| format | Article |
| id | doaj.art-a50a5141f1d941a193835301ea521ff0 |
| institution | Directory Open Access Journal |
| issn | 2072-666X |
| language | English |
| last_indexed | 2024-03-11T00:49:05Z |
| publishDate | 2023-07-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Micromachines |
| spelling | doaj.art-a50a5141f1d941a193835301ea521ff02023-11-18T20:33:17ZengMDPI AGMicromachines2072-666X2023-07-01147142710.3390/mi14071427Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate CompositesÇağın Bolat0Uçan Karakılınç1Bekir Yalçın2Yahya Öz3Çağlar Yavaş4Berkay Ergene5Ali Ercetin6Fatih Akkoyun7Department of Mechanical Engineering, Faculty of Engineering, Samsun University, 55420 Samsun, TurkeyDepartment of Computer Programming, Vocational School of Technical Science, Isparta Applied Science University, 32200 Isparta, TurkeyDepartment of Mechanical Engineering, Faculty of Technology, Afyon Kocatepe University, 03200 Afyonkarahisar, TurkeyAdvanced Composite Materials Technology Center, R&D and Technology Directorate, Turkish Aerospace, 06980 Ankara, TurkeyKarcan Cutting Tools, Organized Industrial Site, 26110 Eskişehir, TurkeyDepartment of Mechanical Engineering, Faculty of Technology, Pamukkale University, 20160 Denizli, TurkeyDepartment of Naval Architecture and Marine Engineering, Maritime Faculty, Bandırma Onyedi Eylül University, 10200 Bandırma, TurkeyDepartment of Mechanical and Metal Technologies, Trabzon Vocational School, Karadeniz Technical University, 61300 Trabzon, TurkeyCarbon fiber-reinforced plastics (CFRPs) have been specially developed to enhance the performance of commercial and military aircraft because of their strength, high stiffness-to-density ratios, and superior physical properties. On the other hand, fasteners and joints of CFRP materials may be weak due to occurring surface roughness and delamination problems during drilling operations. This study’s aim is to investigate the drilling characterization of CFRPs with different drilling parameters and cutting tools. Drilling tests were performed with the Taguchi orthogonal array design (L18: 2^1 3^3). Tests were conducted with three levels of cutting speed (15, 30, 45 m/min), three levels of feed rate (0.05, 0.1, 0.2 mm/rev), two levels of drill diameter (3 and 5 mm), and three different types of drills (two twist drills with a point angle of 138° and 120° and one brad drill). Thrust forces were recorded during drilling tests, and afterwards surface roughness and hole delamination were measured. Obtained results were analyzed with Taguchi and two-way ANOVA. The general tendency was that low cutting speed, high feed rate, and small diameter drill caused an increase in thrust force. Surface roughness decreases with increasing tool diameter, decreasing feed, and cutting speed. Delamination factors of the samples dropped depending on decreasing thrust force levels. Remarkably, it is possible to control the delamination factor values via better surface quality. The brad drill and larger point angle have a negative effect on the drilling quality of CFRPs. According to all results, the cutting speed of 45 m/min and feed rate of 0.05 mm/rev using a type II drill having a 120° point angle and 5 mm diameter (12th trial) and the cutting speed of 30 m/min and feed rate of 0.05 mm/rev using a type II drill having a 120° point angle and 3 mm diameter (2nd trial) were determined as optimum drilling conditions.https://www.mdpi.com/2072-666X/14/7/1427carbon fiber reinforced polymersdrillingthrust forcesurface roughnessdelamination |
| spellingShingle | Çağın Bolat Uçan Karakılınç Bekir Yalçın Yahya Öz Çağlar Yavaş Berkay Ergene Ali Ercetin Fatih Akkoyun Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites Micromachines carbon fiber reinforced polymers drilling thrust force surface roughness delamination |
| title | Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites |
| title_full | Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites |
| title_fullStr | Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites |
| title_full_unstemmed | Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites |
| title_short | Effect of Drilling Parameters and Tool Geometry on the Thrust Force and Surface Roughness of Aerospace Grade Laminate Composites |
| title_sort | effect of drilling parameters and tool geometry on the thrust force and surface roughness of aerospace grade laminate composites |
| topic | carbon fiber reinforced polymers drilling thrust force surface roughness delamination |
| url | https://www.mdpi.com/2072-666X/14/7/1427 |
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