Publication: Drilling of aramid fiber reinforced plastic composite laminates stacks using various bit design geometry in aircraft application
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Date
2023-07-14
Authors
Mohd Rezuan bin Abdul Razak
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Abstract
Drilling AFRP/Al7075-T6 is a challenging due to a two-difference material is attach that its call stack-up material, AFRP laminates is composite and Al7075-T6 is metal, both of that have difference strength and mechanical properties and resulting increasing the thrust force and hole surface roughness if the suitable parameter is not chosen properly. Based on previously literature review on drilling AFRP and stack-up, the parameter such spindle speed, rev/min and feed rate, mm/rev used as a factor to the response of thrust force and hole surface roughness. In this study, the 2000, 4000, and 6000 rev/min as a spindle speed and 0.05, 0.08, and 0.1 mm/rev as a feed rate that was used for running the experiment. The tapered web and burnishing used as drill bit design geometry to drill a stack-up material with dimensional 84 mm x 185 mm with thickness 2.66 mm (AFRP) and 3.30 mm (Al7075-T6). The drilling process machining was done by using CNC machine Fanuc Robodrill α-T2liFLb with attached the Kitsler 5019B Force Dynamometer for measuring the thrust force during drilling stack-up materials. After that, the hole surface roughness was measured by using SURFTEST SV-3100 machine and the hole diameter and hole circularity was measured by using Crysta-Plus M443 coordinate measuring machine (CMM). After collecting the data, the analysis was conducted by ANOVA for maximum thrust force and hole surface roughness using response surface methodology (RSM) in Stat-Ease Design Expert software for statistically the interaction between factor and response. After that, the parameter (spindle speed and feed rate) as a factor was done optimization by RSM with solution proposed with desirability value of 0.863 (tapered web) and 0.826 (burnishing). The value of optimal parameter solution proposed is 5120 rev/min spindle speed, feed rate 0.05 mm/rev for tapered web and 2230 rev/min spindle speed, feed rate 0.05 mm/rev for burnishing to minimize the response (thrust force and hole surface roughness) with expected value 67.628 N (AFRP thrust force), 155.499 N (Al7075-T6 thrust force), 2.336 μm (AFRP hole surface roughness), 0.301 μm (Al7075-T6 hole surface roughness) for tapered web drill bit design geometry and 82.678 N (AFRP thrust force), 198.666 N (Al7075-T6 thrust force), 1.119 μm (AFRP hole surface roughness), 0.457 μm (Al7075-T6 hole surface roughness) for burnishing drill bit design geometry. Lastly, from the result shows the tapered web drill bit design geometry is more the efficient for drilling the stack-up materials (AFRP/Al7075-T6) for a single-shot drilling in term of thrust force and hole surface roughness.