单层金刚石工具螺旋钻削复合材料的性能比较

SULTANAIreen; 史忠德; ATTIAHelmi; THOMSONVincent

doi:10.13394/j.cnki.jgszz.2023.1003

Comparative evaluation of the performances of single layer diamond tools in orbital drilling of composites

doi: 10.13394/j.cnki.jgszz.2023.1003

1.
McGill University, Montréal H3A 0C3, Québec, , Canada
2.
Aerospace Manufacturing Technology Centre, Aerospace Research Centre, National Research Council Canada, Montréal H3T 1J4, Québec, Canada

摘要

摘要: 使用不同形状、不同磨粒尺寸的单层金刚石工具以螺旋钻孔方式加工多向碳纤维-环氧树脂层压板，比较各工具的加工性能。在复合材料上钻孔时，和传统钻削相比，螺旋钻孔是更先进和完善的方法。选择7种不同工具开展性能试验，研究金刚石磨粒尺寸、刀具槽口类型和末端几何形状对钻进力、温度、钻进缺陷和表面完整性的影响。结果发现高速旋转钻削可以显著降低钻削力。使用磨粒尺寸更小的工具进行加工，可以改善钻孔表面粗糙度，但是其钻削力更大、钻削温度更高。带有槽口的工具可以减轻工具表面堵塞。和平直末端或无槽口的工具相比，球形末端的工具性能更好。
- 螺旋钻孔 /
- CFRP /
- 单层金刚石工具 /
- 钻削力 /
- 温度 /
- 表面完整性
Abstract: Orbital drilling is an advanced and improved technique over conventional drilling in producing holes in composites. Single layer diamond tools of different geometries and grain sizes were experimentally investigated to explore their performances in orbital drilling of multidirectional carbon/epoxy laminates. The effects of diamond grain sizes, types of flutes and tool end geometries were evaluated in terms of drilling forces, temperatures, drilling-induced defects and surface integrity. It was found that drilling with high spindle rotational speed results in significantly reduced forces. Tools with smaller grain sizes improve hole surface roughness at the cost of increased drilling forces and temperatures. Provision of flutes on tools lowers the tendency of tool clogging. Ball end tools perform better than tools with flat end geometry and without flutes.
- helical drilling /
- CFRP /
- single layer diamond tool /
- drilling force /
- temperature /
- surface integrity

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Figure 1. Different cutting tools

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Figure 2. Experimental setup

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Figure 3. Schematic diagram of the force components

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Figure 4. Typical force signals

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Figure 5. Variation of F_R with respect to spindle speed for axial pitch of (a) 0.5 mm (b) 1.0 mm

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Figure 6. Variation of F_th with respect to spindle speed for axial pitch of (a) 0.5 mm (b) 1.0 mm

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Figure 7. Peripheral resultant forces

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Figure 8. Peripheral speed variation in ball end tools

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Figure 9. (a) Grain spacing and (b) forces in CORE60

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Figure 10. Thrust forces for different tools

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Figure 11. (a) Fresh tool (b) Clogged FNF60 (c) Clogged FHF60

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Figure 12. Optical micrograph of clogged tool end surface

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Figure 13. Infrared imaging during drilling (N = 40,000 r/min, f_O = 1,500 mm/min, and p = 1.0 mm)

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Figure 14. Calibration curves

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Figure 15. Variation of cutting tool temperature at exit with spindle speeds

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Figure 16. Drilling temperatures for different cutting tools

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Figure 17. A typical drilled hole by diamond tools (a) and its closer view (b)

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Figure 18. Hole regions for various diamond tools

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Figure 19. Variations of diametric deviations at axial pitch of (a) 0.5 mm and (b) 1.0 mm

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Figure 20. Diametric deviations for different drilling tools

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Figure 21. Variation of hole circularities for axial pitch of (a) 0.5 mm and (b) 1.0 mm

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Figure 22. Circularity of the holes for different tool geometries

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Figure 23. Variation of surface roughness for axial pitch of (a) 0.5 mm and (b) 1.0 mm

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Figure 24. Surface roughness of the drilled holes

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