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Proposal of a tilted helical milling technique for high quality hole drilling of CFRP: kinetic analysis of hole formation and material removal

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Abstract

Carbon fiber reinforced plastic (CFRP) is used for various mechanical structures because of its superior mechanical and physical properties. Industrial applications of CFRP require high quality, efficiently drilled holes. However, it is difficult for conventional methods, such as drilling, helical milling, and so on to meet industry requirements. Therefore, this study proposed a novel method for drilling holes in CFRP products. This new method is performed by replacing the revolving motion of the tool in conventional helical milling (CHM) with conical pendulum motion, in which the tool axis is tilted toward the hole axis at a certain angle, consequently called tilted helical milling (THM). As a step toward the establishment of the new method, in this work, the hole formation process, the cross-sectional area of work materials removed per tool revolution, and the zero cutting speed point problem in THM were theoretically compared with those in CHM. Then, experiments were performed to confirm the theoretical analysis in terms of the variations in the cross section profile of the drilled hole, the drilling forces, the hole quality at entrance/exit, and the chip removal. The obtained results revealed that during hole drilling by THM, a circumferential V-groove exists between the end face of the tool and the bottom of the hole, whereas in CHM, this phenomenon does not occur. This fact is beneficial to timely chip removal, drilling force reduction, and zero cutting speed point problem avoidance. Subsequently, high quality holes can be successfully obtained with high efficiency by THM.

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Funding

A portion of this work was conducted under the financial supports of the Mikiya Science and Technology Promotion Foundation and the Mazak Foundation. This research is supported by the National Natural Science Foundation of China (Grant No. 51405218).

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Authors and Affiliations

  1. Department of Machine Intelligence and Systems Engineering, Akita Prefectural University, Yurihonjo, Akita, 0150055, Japan

    Qiang Wang, Yongbo Wu, Teruo Bitou, Mitsuyoshi Nomura & Tatsuya Fujii

  2. Department of Mechanical and Energy Engineering, Southern University of Science and Technology, Shenzhen, Guangdong, 518055, China

    Qiang Wang & Yongbo Wu

Authors
  1. Qiang Wang
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  2. Yongbo Wu
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  3. Teruo Bitou
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  4. Mitsuyoshi Nomura
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  5. Tatsuya Fujii
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Correspondence to Yongbo Wu.

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Wang, Q., Wu, Y., Bitou, T. et al. Proposal of a tilted helical milling technique for high quality hole drilling of CFRP: kinetic analysis of hole formation and material removal. Int J Adv Manuf Technol 94, 4221–4235 (2018). https://doi.org/10.1007/s00170-017-1106-3

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  • DOI: https://doi.org/10.1007/s00170-017-1106-3

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