Optimization for drilling process of metal-composite aeronautical structures

Metal-composite laminates and joints are applied in aircraft manufacturing and maintenance (repairing) using aluminum alloys (AA) and glass fiber-reinforced polymer (GFRP). In these applications, drilling has a prominent place due to its vast application in aeronautical structures’ mechanical joints...

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Autores principales:	Devitte Cristiano, Souza Gabriel S. C., Souza André J., Tita Volnei
Formato:	article
Lenguaje:	EN
Publicado:	De Gruyter 2021
Materias:	drilling metal-composite laminates delamination factor thrust force box–behnken design Materials of engineering and construction. Mechanics of materials TA401-492
Acceso en línea:	https://doaj.org/article/612a5d059cd34decb52b3f4964fedcc0
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id	oai:doaj.org-article:612a5d059cd34decb52b3f4964fedcc0
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spelling	oai:doaj.org-article:612a5d059cd34decb52b3f4964fedcc02021-12-05T14:11:03ZOptimization for drilling process of metal-composite aeronautical structures2191-035910.1515/secm-2021-0027https://doaj.org/article/612a5d059cd34decb52b3f4964fedcc02021-05-01T00:00:00Zhttps://doi.org/10.1515/secm-2021-0027https://doaj.org/toc/2191-0359Metal-composite laminates and joints are applied in aircraft manufacturing and maintenance (repairing) using aluminum alloys (AA) and glass fiber-reinforced polymer (GFRP). In these applications, drilling has a prominent place due to its vast application in aeronautical structures’ mechanical joints. Thus, this study presents the influence of uncoated carbide drills (85C, 86C, H10N), cutting speeds (v c = 20, 40, and 60 m min−1), and feed rates (f = 0.05, 0.15, and 0.25 mm rev−1) on delamination factor, thrust force (Ft{F}_{\text{t}}), and burr formation in dry drilling metal-composite laminates and joints (AA2024/GFRP/AA2024). Experiments were performed, analyzed, and optimized using the Box–Behnken statistical design. Microscopic digital images for delamination evaluation, piezoelectric dynamometer for thrust force acquisition, and burr analysis were considered. The major finding was that the thrust force during drilling depends significantly on the feed rate. Another significant factor was the influence of the drill type (combined or not with feed rate). In fact, it was verified that the feed rate and the drill type were the most significant parameters on the delamination factor, while the feed rate was the most relevant on thrust force. The cutting speed did not affect significantly thrust force and delamination factor at exit(FdaS)\hspace{.25em}({F}_{{\text{da}}_{\text{S}}}). However, the combination f × v c was significant in delamination factor at entrance (FdaE)\text{ }({F}_{{\text{da}}_{\text{E}}}). Based on the optimized input parameters, they presented lower values for delamination factors (FdaE=1.18{F}_{{\text{da}}_{\text{E}}}=1.18 and FdaS=1.33{F}_{{\text{da}}_{\text{S}}}=\hspace{.25em}1.33) and thrust force (Ft=67.3N{F}_{\text{t}}=67.3\hspace{.5em}\text{N}). These values were obtained by drilling the metal-composite laminates with 85C-tool, 0.05 mm rev−1 feed rate, and 20 m min−1 cutting speed. However, the burrs at the hole output of AA2024 were considered unsatisfactory for this specific condition, which implies additional investigation.Devitte CristianoSouza Gabriel S. C.Souza André J.Tita VolneiDe Gruyterarticledrillingmetal-composite laminatesdelamination factorthrust forcebox–behnken designMaterials of engineering and construction. Mechanics of materialsTA401-492ENScience and Engineering of Composite Materials, Vol 28, Iss 1, Pp 264-275 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	drilling metal-composite laminates delamination factor thrust force box–behnken design Materials of engineering and construction. Mechanics of materials TA401-492
spellingShingle	drilling metal-composite laminates delamination factor thrust force box–behnken design Materials of engineering and construction. Mechanics of materials TA401-492 Devitte Cristiano Souza Gabriel S. C. Souza André J. Tita Volnei Optimization for drilling process of metal-composite aeronautical structures
description	Metal-composite laminates and joints are applied in aircraft manufacturing and maintenance (repairing) using aluminum alloys (AA) and glass fiber-reinforced polymer (GFRP). In these applications, drilling has a prominent place due to its vast application in aeronautical structures’ mechanical joints. Thus, this study presents the influence of uncoated carbide drills (85C, 86C, H10N), cutting speeds (v c = 20, 40, and 60 m min−1), and feed rates (f = 0.05, 0.15, and 0.25 mm rev−1) on delamination factor, thrust force (Ft{F}_{\text{t}}), and burr formation in dry drilling metal-composite laminates and joints (AA2024/GFRP/AA2024). Experiments were performed, analyzed, and optimized using the Box–Behnken statistical design. Microscopic digital images for delamination evaluation, piezoelectric dynamometer for thrust force acquisition, and burr analysis were considered. The major finding was that the thrust force during drilling depends significantly on the feed rate. Another significant factor was the influence of the drill type (combined or not with feed rate). In fact, it was verified that the feed rate and the drill type were the most significant parameters on the delamination factor, while the feed rate was the most relevant on thrust force. The cutting speed did not affect significantly thrust force and delamination factor at exit(FdaS)\hspace{.25em}({F}_{{\text{da}}_{\text{S}}}). However, the combination f × v c was significant in delamination factor at entrance (FdaE)\text{ }({F}_{{\text{da}}_{\text{E}}}). Based on the optimized input parameters, they presented lower values for delamination factors (FdaE=1.18{F}_{{\text{da}}_{\text{E}}}=1.18 and FdaS=1.33{F}_{{\text{da}}_{\text{S}}}=\hspace{.25em}1.33) and thrust force (Ft=67.3N{F}_{\text{t}}=67.3\hspace{.5em}\text{N}). These values were obtained by drilling the metal-composite laminates with 85C-tool, 0.05 mm rev−1 feed rate, and 20 m min−1 cutting speed. However, the burrs at the hole output of AA2024 were considered unsatisfactory for this specific condition, which implies additional investigation.
format	article
author	Devitte Cristiano Souza Gabriel S. C. Souza André J. Tita Volnei
author_facet	Devitte Cristiano Souza Gabriel S. C. Souza André J. Tita Volnei
author_sort	Devitte Cristiano
title	Optimization for drilling process of metal-composite aeronautical structures
title_short	Optimization for drilling process of metal-composite aeronautical structures
title_full	Optimization for drilling process of metal-composite aeronautical structures
title_fullStr	Optimization for drilling process of metal-composite aeronautical structures
title_full_unstemmed	Optimization for drilling process of metal-composite aeronautical structures
title_sort	optimization for drilling process of metal-composite aeronautical structures
publisher	De Gruyter
publishDate	2021
url	https://doaj.org/article/612a5d059cd34decb52b3f4964fedcc0
work_keys_str_mv	AT devittecristiano optimizationfordrillingprocessofmetalcompositeaeronauticalstructures AT souzagabrielsc optimizationfordrillingprocessofmetalcompositeaeronauticalstructures AT souzaandrej optimizationfordrillingprocessofmetalcompositeaeronauticalstructures AT titavolnei optimizationfordrillingprocessofmetalcompositeaeronauticalstructures
_version_	1718371424403456000

Optimization for drilling process of metal-composite aeronautical structures

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