Publication: Hole quality assessment of drilled carbon fiber reinforced polymer (cfrp) panel using three type of drill bit
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Date
2024-08-01
Authors
Muhammad Faris Shauqi, Kamaruzaman
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Abstract
Drilling carbon fiber reinforced polymer (CFRP) is essential for maintaining thrust force and hole quality through multiple drilling processes. The aerospace industry demands excellent hole quality for its drilling procedures involving highly abrasive CFRP. While many twist drills exhibit good hole quality performance, this research explores three different unique twist drill bit geometries like tapered web, burnishing drill bit, and subland reamer which focusing on helix angle, primary clearance, point angle, and chisel angle. These drill bits, made of powder tungsten carbide undergoing the sintering process, are used to drill CFRP panels. The main objective of this research is to optimize drilling parameters to minimize thrust force, hole surface roughness, hole diameter error, and hole delamination across all unique drill bit designs. The study considers spindle speed (ranging from 1500 rev/min to 4500 rev/min) and feed rate (ranging from 0.05 mm/rev to 0.1 mm/rev). The results are then evaluated using analysis of variance (ANOVA) to determine the impact of different drilling parameters on the maximum thrust force and hole integrity. The findings suggest that the best drilling parameters are observed with R1 (1500 rev/min and 0.05 mm/rev) for tapered web, R1 (1500 rev/min and 0.05 mm/rev) for burnishing, and R2 (1500 rev/min and 0.075 mm/rev) for subland reamer drill bit designs, showing the least thrust force, lowest hole surface roughness, minimal hole diameter error, and least hole delamination. In conclusion, thrust force is directly proportional to hole surface roughness, hole diameter, and hole delamination when drilling CFRP in a single shot operation. Higher drilling parameters for each drill bit design result in increased values for all responses, emphasizing the need to improve twist drill designs in terms of geometries for optimal performance in all attempts.