Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks

Carbon Fibre Composite (CFC) and titanium (Ti) alloys have been widely employed in the aerospace industry due to their high strength to weight ratios. For making a military aircraft body, these materials are usually stacked together with titanium alloys serving as the airframe, while CFC is the oute...

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Main Authors:	Dahnel, Aishah Najiah, Barnes, Stuart, Ascroft, Helen, Gloger, Maximilian
Format:	Conference or Workshop Item
Language:	English
Published:	American Society of Mechanical Engineers (ASME) 2015
Subjects:	T175 Industrial research. Research and development TA401 Materials of engineering and construction TS200 Metal manufactures. Metalworking
Online Access:	http://irep.iium.edu.my/69185/ http://irep.iium.edu.my/69185/ http://irep.iium.edu.my/69185/ http://irep.iium.edu.my/69185/7/69185%20ANALYSIS%20OF%20TOOL%20WEAR.pdf

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spelling	iium-691852019-04-03T00:36:26Z http://irep.iium.edu.my/69185/ Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks Dahnel, Aishah Najiah Barnes, Stuart Ascroft, Helen Gloger, Maximilian T175 Industrial research. Research and development TA401 Materials of engineering and construction TS200 Metal manufactures. Metalworking Carbon Fibre Composite (CFC) and titanium (Ti) alloys have been widely employed in the aerospace industry due to their high strength to weight ratios. For making a military aircraft body, these materials are usually stacked together with titanium alloys serving as the airframe, while CFC is the outer skin. Drilling is often performed in one shot from the CFC outer skin through to the titanium alloy airframe for the purpose of assembling them by mechanical means using rivets, screws, nuts and bolts. Conventional drilling of these CFC/Ti stacks, however, often results in two major issues; rapid tool failure and poor hole quality. This paper considers the potential of employing Ultrasonic Assisted Drilling (UAD) on stack materials in order to improve tool life and hole quality. Experiments comparing conventional drilling and UAD on CFC/Ti6Al4V stack using reground 6.121 mm-diameter TiAlN coated tungsten carbide twist drills are presented. Reground drills were used by way of replicating typical current practice in industry. A constant cutting speed and feed rate of 50 m/min and 0.05 mm/rev, respectively was used in both experiments. During UAD experiments, ultrasonic amplitude and frequency was fixed at 2.6 µm and 42.7 kHz, respectively. A total of 100 holes were drilled in the stacks during each drilling processes (conventional drilling and UAD). Machinability was assessed in terms of thrust forces, tool wear, hole diameter, CFC delamination and titanium burr. Thrust forces were measured using a dynamometer; tool wear was examined using an optical microscope and a Scanning Electron Microscope (SEM); and holes diameter were measured using a bore micrometer. Hole defects; CFC entry delamination was examined and quantified using an optical microscope, while titanium exit burr were investigated using both an optical microscope and a depth gauge. The dominant types of tool wear during drilling of CFC/Ti6Al4V stacks were caused by titanium adhesion/fusion on the cutting edges. In addition, abrasive wear caused by abrading carbon fibres against cutting edges were also observed. Poor hole quality of the stacks included inconsistent diameter of CFC and titanium holes; CFC delamination at the hole entrance and burr formation as the drill exited the titanium. The difference in thrust forces produced by conventional drilling and UAD were minor. It was observed that UAD resulted in less tool wear rate and a reduction of adhered titanium alloy on the cutting edges, more consistent hole diameters and less titanium burr compared to conventional drilling. However, larger CFC delamination was observed during UAD than conventional drilling. American Society of Mechanical Engineers (ASME) 2015 Conference or Workshop Item PeerReviewed application/pdf en http://irep.iium.edu.my/69185/7/69185%20ANALYSIS%20OF%20TOOL%20WEAR.pdf Dahnel, Aishah Najiah and Barnes, Stuart and Ascroft, Helen and Gloger, Maximilian (2015) Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks. In: ASME 2015 International Mechanical Engineering Congress and Exposition, IMECE 2015, 13th-19th November 2015, Houston, Texas, USA. http://proceedings.asmedigitalcollection.asme.org/proceeding.aspx?articleid=2500469 10.1115/IMECE2015-50416
repository_type	Digital Repository
institution_category	Local University
institution	International Islamic University Malaysia
building	IIUM Repository
collection	Online Access
language	English
topic	T175 Industrial research. Research and development TA401 Materials of engineering and construction TS200 Metal manufactures. Metalworking
spellingShingle	T175 Industrial research. Research and development TA401 Materials of engineering and construction TS200 Metal manufactures. Metalworking Dahnel, Aishah Najiah Barnes, Stuart Ascroft, Helen Gloger, Maximilian Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks
description	Carbon Fibre Composite (CFC) and titanium (Ti) alloys have been widely employed in the aerospace industry due to their high strength to weight ratios. For making a military aircraft body, these materials are usually stacked together with titanium alloys serving as the airframe, while CFC is the outer skin. Drilling is often performed in one shot from the CFC outer skin through to the titanium alloy airframe for the purpose of assembling them by mechanical means using rivets, screws, nuts and bolts. Conventional drilling of these CFC/Ti stacks, however, often results in two major issues; rapid tool failure and poor hole quality. This paper considers the potential of employing Ultrasonic Assisted Drilling (UAD) on stack materials in order to improve tool life and hole quality. Experiments comparing conventional drilling and UAD on CFC/Ti6Al4V stack using reground 6.121 mm-diameter TiAlN coated tungsten carbide twist drills are presented. Reground drills were used by way of replicating typical current practice in industry. A constant cutting speed and feed rate of 50 m/min and 0.05 mm/rev, respectively was used in both experiments. During UAD experiments, ultrasonic amplitude and frequency was fixed at 2.6 µm and 42.7 kHz, respectively. A total of 100 holes were drilled in the stacks during each drilling processes (conventional drilling and UAD). Machinability was assessed in terms of thrust forces, tool wear, hole diameter, CFC delamination and titanium burr. Thrust forces were measured using a dynamometer; tool wear was examined using an optical microscope and a Scanning Electron Microscope (SEM); and holes diameter were measured using a bore micrometer. Hole defects; CFC entry delamination was examined and quantified using an optical microscope, while titanium exit burr were investigated using both an optical microscope and a depth gauge. The dominant types of tool wear during drilling of CFC/Ti6Al4V stacks were caused by titanium adhesion/fusion on the cutting edges. In addition, abrasive wear caused by abrading carbon fibres against cutting edges were also observed. Poor hole quality of the stacks included inconsistent diameter of CFC and titanium holes; CFC delamination at the hole entrance and burr formation as the drill exited the titanium. The difference in thrust forces produced by conventional drilling and UAD were minor. It was observed that UAD resulted in less tool wear rate and a reduction of adhered titanium alloy on the cutting edges, more consistent hole diameters and less titanium burr compared to conventional drilling. However, larger CFC delamination was observed during UAD than conventional drilling.
format	Conference or Workshop Item
author	Dahnel, Aishah Najiah Barnes, Stuart Ascroft, Helen Gloger, Maximilian
author_facet	Dahnel, Aishah Najiah Barnes, Stuart Ascroft, Helen Gloger, Maximilian
author_sort	Dahnel, Aishah Najiah
title	Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks
title_short	Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks
title_full	Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks
title_fullStr	Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks
title_full_unstemmed	Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks
title_sort	analysis of tool wear and hole quality during ultrasonic assisted drilling (uad) of carbon fibre composite (cfc)/titanium alloy (ti6al4v) stacks
publisher	American Society of Mechanical Engineers (ASME)
publishDate	2015
url	http://irep.iium.edu.my/69185/ http://irep.iium.edu.my/69185/ http://irep.iium.edu.my/69185/ http://irep.iium.edu.my/69185/7/69185%20ANALYSIS%20OF%20TOOL%20WEAR.pdf
first_indexed	2023-09-18T21:38:12Z
last_indexed	2023-09-18T21:38:12Z
_version_	1777412963419815936

Analysis of tool wear and hole quality during Ultrasonic Assisted Drilling (UAD) of Carbon Fibre Composite (CFC)/titanium alloy (Ti6Al4V) stacks

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