EFFECT OF ULTRASONIC TORSIONAL MODE VIBRATION CUTTING ON DRILLING IN CFRP LAMINATES
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1 EFFET OF ULTRASONI TORSIONAL MOE VIRATION UTTING ON RILLING IN FRP LAMINATES H.Ygisit Professor-octor ept. of ontrol nd omputer Engineering Vice President of Numzu Ntionl ollege of Tecnology 3600 Ook, Numzu-city, Sizuok-pref JAPAN INTROUTION Wide spred pplictions of composite mteril ve been significntly growing in erospce, nvl, spce nd utomotive industries. Especilly, FRP ( crbon fiber reinforced plstics ) lmintes ve iger strengt/weigt rtio ( bout ten times lrger tensile strengt tn dvnced luminum lloy in spite of bout one lf specific grvity ) nd ig et resistnce. Terefore, recently most of wing, til ssembly nd body of ircrft ve been mnufctured by ssembling severl prts mde of FRP lmintes. olting nd riveting re currently te preferred metods for fstening composite skins to te metl or oter composite prts in ssembly of erospce nd utomotive composite structures [1]. Nmely, drilling of FRP lmintes is indispensble for mnufcturing ircrft nd utomotive composite structure nd te qulity of drilled oles strongly ffects te ftigue strengt of te structure besides te relibility of ircrft. Te prticulr objective of te present work ws to conduct drilling experiments of FRP lmintes in order to investigte te cutting mecnism nd te effects of ultrsonic torsionl mode vibrtion cutting. Experimentl work ws performed to crcterize mjor ole qulity prmeter nd cutting mecnism encountered wen drilling FRP lmintes nd lso to exmine specific drilling ssisted by ultrsonic torsionl mode vibrtion. Inner surfce texture of drilled ole, ole dimeter nd tool life were investigted nd discussed by compring te results of conventionl drilling wit tose of specific drilling ssisted by ultrsonic torsionl mode vibrtion [2]. EXPERIMENTAL SETUP AN PROEURE Mteril Systems FRP ws mde from combining crbon fiber clusters wit epoxy-resin mtrix, to crete strong, ig temperture composite. Te FRP lmintes were mde of 11 plies of FRP oriented s follows: ( 0, 90, 0, 90, 0, 90, 0, 90, 0, 90, 0), nd bot te upper nd te lower two plies re tinner tn mid 7 plies. Te workpiece sown in Fig.1 ws consolidted from lmintes of one oriented crbon fiber prepreg using te utoclve metod. Fiber orienttion 90 Fiber orienttion FIGURE 1. Sectioned view of FRP lmintes. 0
2 rilling Experimentl Metod nd Procedure rilling experimentl setup ssisted by ultrsonic torsionl mode vibrtion consists of vibrtion unit, oscilltion unit nd disply unit s sown in Fig. 2. Te tper snk of vibrtion unit is ttced rigidly to te min spindle of N milling mcine. Te electric control signl from oscilltion unit oscilltes torsionlly t 27 khz te twist drill ttced to vibrtion unit, wic re rotting s one body wit te min spindle of te milling mcine. Min spindle of N milling mcine Top view Side view Top view Side view FIGURE 3. Appernce of coted cemented crbide fiber drill used. isply unit TALE 1. Te summry of experimentl conditions for FRP lmintes. Oscilltion unit Vibrtion unit FIGURE 2. Scemtic drilling experimentl setup ssisted by ultrsonic torsionl mode vibrtion. isply unit expresses resonnt frequency, tip mplitude of twist drill constntly, nd supplied voltge, mpere nd electric power selectively during running of te drilling system. oted cemented crbide fiber drills of 3 mm dimeter, wic ve pir of specil cutting edge sown in Fig.3, were used for ll experiments. As sown in Fig.3, tinning is pplied to te cisel edge but mrgin does not exist being different from conventionl twist drill. Te summry of experimentl conditions for FRP lmintes is listed in Tble 1. RESULTS AN ISUSSION utting Mecnism Te vrition of reltive ngle between fiber orienttion nd cutting direction is sown in Fig.4()(b). () nd (b) in Fig. 4 sow te ply of fiber orienttion 0 nd 90 respectively. In tese figures, te reltive ngle t A, E in () nd, e in (b) is 90, nd te ngle t, G nd c, g is 0, nd te ngle t, F nd b, f is -45, nd te ngle t, H nd d, is +45 respectively. Inner surfce textures, wic re mesured
3 () Ply of fiber orienttion 0 () Reltive ngle of 90 t position (b) Ply of fiber orienttion 0 FIGURE 4. Reltive ngle between fiber orienttion nd cutting direction. (b) Reltive ngle of 0 t position using lser bem scnning microscope, t reltive ngle of 90, 0 nd ±45 re sown in Fig.5()(b)(c). () t reltive ngle of 90 sows te lmost smoot surfce but severl drk dots like circle re found. On te oter nd, (b) t reltive ngle of 0 sows te scrtced trces of bout 400µm widt, wic would be cused by rubbing of cutting edges. In (c) t reltive ngle of ±45, two drk res re seen t of te ngle +45. From more detiled observtions it is confirmed tt te drk res form te crters of 5070 µm dept (c) Reltive ngle of +45 t position nd -45 t position b. FIGURE 5. Inner surfce texture t reltive ngle of 90, 0 nd ±45. Hole Qulity Assessment As pplicble FRP lmintes, ole qulity consists of mteril integrity, ole dimeter nd roundness, inner surfce texture, nd ole exit dmge of drilled oles. Te present work focuses te subject on inner surfce texture, ole dimeter nd tool life. Effects of Ultrsonic Torsionl Mode Vibrtion utting on Inner Surfce Texture To exmine te effect of ultrsonic torsionl mode vibrtion cutting on te inner surfce texture of drilled ole, te texture ws observed using lser bem scnning microscope fter being cut t te center of ole wit n brsive wter jet cutting. Figure 6 () nd (b) sow te inner surfce texture of lf ole t 19t ole by conventionl drilling nd tt by specific drilling ssisted by ultrsonic torsionl mode vibrtion respectively. In Fig. 6 (), t only position of nd of te
4 200m 200m 200m () 19t ole by conventionl drilling b b b 200m 200m 200m (b) 19t ole ssisted by ultrsonic torsionl mode vibrtion FIGURE 6. omprison between inner surfce texture of 19t ole by conventionl drilling nd tt ssisted by ultrsonic torsionl mode vibrtion.
5 reltive ngle of +45, te drk res re found remrkbly. From te similr observtions for te inner surfce opposite lf ole to tt in Fig. 6() te drk res re found t te position of d nd H. sed on te more detiled observtions using lser bem scnning microscope, te fct tt te drk res form sllow crters of µm dept is scertined. However, in Fig. 6(b) ssisted by ultrsonic torsionl mode vibrtion, tey re not found scrcely t te sme positions of nd. Te occurrence of te sllow crters t only te reltive ngle of +45 for conventionl drilling is considered s follows. ompring te surfce texture t te position of reltive ngle 0 in Fig. 9() wit te sme tt in Fig. 9(b), te widt of scrtced trces of cutting edges is clerly different. Nmely, in Fig. 9(b) ssisted by ultrsonic torsionl mode vibrtion, becuse instntneous cutting is repeted times during one second, te bility for cutting edge to cut crbon fiber cluster would be significntly improved. As result te widt of scrtced trces cused by rubbing of cutting edges ginst crbon fiber cluster nd epoxy-resin is nrrowed s sown by te wite rrow in te Figures M of Fig. 9() nd (b). Since sortening te rubbing durtion contributes to decrese et genertion by friction, te temperture increse of cutting edges, crbon fiber cluster nd epoxy-resin is restrined. As sown in Tble 2, te terml conductivity of epoxy-resin is muc smller tn crbon fiber nd lso te crbon fiber cluster s better terml conductivity in te fiber TALE 2. omprison of coefficient of terml conductivity. orienttion tn tt in oter direction. Terefore, during conventionl drilling te et generted by rubbing t position is conducted to te following position troug crbon fiber cluster nd te temperture of position will be risen. It is well-known tt epoxy-resin becomes brittle t te temperture over bout 180 of glss trnsition temperture. From te bove-mentioned considertion, it is reveled tt te et genertion by rubbing nd te crcteristics of terml conductivity of crbon fiber nd epoxy-resin would be te prime cuse of sllow crter s genertion t te positions,, d nd H of te reltive ngle +45. Figure 7 () nd (b) sow te reltionsip between number of crter, wic re found on te inner surfce of lf ole, nd number of mcined ole, nd () is te reltionsip during () onventionl drilling (b) Specific drilling ssisted by ultrsonic vibrtion FIGURE 7. Reltionsip between number of crter on lf ole nd number of mcined ole.
6 conventionl drilling nd (b) is tt during specific drilling ssisted by ultrsonic torsionl mode vibrtion, respectively. From () nd (b) in Fig. 7, te crter ws generted from first ole during conventionl drilling, neverteless it ws found fter 30t ole during specific drilling ssisted by ultrsonic torsionl mode vibrtion. Effect of Ultrsonic Torsionl Mode Vibrtion utting on Hole imeter Figure 8 sows te reltionsip between devition of ole dimeter from 3 mm nd number of mcined ole. As sown in Fig. 8, it is seen tt scttering of devition of ole dimeter from 3 mm cn be reduced from 16 µm to 8 µm by ssist of ultrsonic torsionl mode vibrtion. Te lrge scttering of ole dimeter during conventionl drilling would be induced by te occurrence of crter on te inner surfce of ole. FIGURE 8. Reltionsip between devition of ole dimeter nd number of mcined ole. Effect of Ultrsonic Torsionl Mode Vibrtion utting on Tool Life sed on te criteri of tool life wen te wer widt of circumferentil cutting edge reces to 0.07mm, effect of ultrsonic torsionl mode vibrtion cutting on tool life of drill ws exmined. Since tool life is ffected by te occurrence of micro-cipping, drilling tests were executed five times in conventionl drilling nd lso in specific one ssisted by ultrsonic torsionl mode vibrtion respectively. As sown in Fig. 9, te ssist of FIGURE 9. omprison of tool life between ultrsonic conventionl torsionl drilling mode nd specific vibrtion one. to drilling ultrsonic torsionl mode vibrtion to drilling FRP lmintes is significntly effective to extend te tool life of cemented crbide fiber drill. It cn be understood torougly tt te extension of tool life is cused by temperture increse being restrined t cutting edge due to decrese of rubbing durtion between cutting edge nd crbon fiber cluster. REFERENES [1] Wurzynik, P. Aerospce Mnufcturing- Len FIGHTER. Mecnicl Engineering. 2005; Vol.134, No.3: [2] Ygisit H. utting Mecnism of rilling FRP Lmintes nd Effect of Ultrsonic Torsionl Mode Vibrtion utting. Trnsctions of te Nort Americn Mnufcturing Reserc Institution of SME. 2006; 34:
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