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3D Finite Element Model on Drilling of CFRP with Numerical Optimization and Experimental Validation
1Department of Mechanical Engineering, McMaster University, 1280 Main St. W, Hamilton, ON L8S 4L8, Canada.
Materials (Basel, Switzerland)
|April 3, 2021
Summary
This study developed a Finite Element (FE) model to predict hole quality in Carbon Fibre-Reinforced Plastic (CFRP) drilling. The model accurately predicts drilling forces and damage, improving optimization for CFRP machining.
Area of Science:
- Materials Science
- Mechanical Engineering
- Manufacturing Processes
Background:
- Drilling Carbon Fibre-Reinforced Plastic (CFRP) presents challenges in achieving desired hole quality while maintaining efficient production and minimizing tool wear.
- Numerical modeling is crucial for optimizing CFRP drilling parameters, focusing on material removal rates and hole integrity.
Purpose of the Study:
- To develop and validate a macro-Finite Element (FE) model for predicting the impact of drill tip geometry on hole quality during CFRP drilling.
- To investigate the influence of various numerical parameters on computational efficiency and prediction accuracy.
Main Methods:
- A macro-mechanical material model was created, treating CFRP as an Equivalent Homogeneous Material (EHM).
- Numerical analysis explored mass scaling, bulk viscosity, friction, strain rate strengthening, and cohesive surface modeling to optimize computational time and minimize dynamic effects.
- Experimental drilling was conducted using double-point angle and "candle-stick" profile drills to validate the FE model's predictions of drilling forces and hole quality.
Main Results:
- The 3D FE model accurately predicted thrust forces and hole quality for different drill tip geometries, with less than 9% difference from experimental measurements.
- Cohesive surface modeling significantly improved the accuracy of the FE predictions.
- Simulated force signatures closely matched experimental profiles, and reduced inter-ply damage was observed with the double-angle drill tip, consistent with FE predictions.
Conclusions:
- The developed macro-FE model provides a reliable tool for predicting drilling performance and hole quality in CFRP materials.
- The study demonstrates the effectiveness of cohesive surface modeling in enhancing FE analysis accuracy for CFRP drilling.
- Drill tip geometry, specifically the double-angle profile, can be optimized using such models to minimize damage during CFRP machining.
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