Influence of machining parameters and new nano-coated tool on drilling performance of CFRP/Aluminium sandwich
Résumé
Drilling and fastening of hybrid materials in one-shot operation reduces cycle time of assembly of aerospace structures. One of the most common problems encountered in automatic drilling and riveting of multimaterial is that the continuous chips curl up on the body of the tool. Drilling of carbon fiber reinforced plastic (CFRP) is manageable, but when the minute drill hits the aluminium (Al) or titanium (Ti), the hot and continuous chips produced during machining considerably damage the CFRP hole. This study aims to solve this problem by employing nano-coated drills on multimaterial made of CFRP and aluminium alloy. The influence of cutting parameters on the quality of the holes, chip formation and tool wear were also analyzed. Two types of tungsten carbide drills were used for the present study, one with nano-coating and the other, without nano coating. The experimental results indicated that the shape and the size of the chips are strongly influenced by feed rate. The thrust force generated during drilling of the composite plate with coated drills was 10-15% lesser when compared to that generated during drilling with uncoated drills; similarly, the thrust force in the aluminium alloy was 50% lesser with coated drills when compared to thrust force generated without coated drills. Thus, the use of nano-coated drills significantly reduced the surface roughness and thrust force when compared with uncoated tools.