Experimental Study on Grinding for Hole-Making of 2.5D C/SiC Composites Using Diamond Core Drills

Area of Science:

• Materials Science
• Manufacturing Engineering

Background:

• 2.5D C/SiC composites exhibit high hardness and brittleness, leading to defects like fiber fracture and burr formation during hole-making.
• Machining these advanced composites presents challenges due to their inherent material properties.

Purpose of the Study:

• To investigate the material removal mechanism, tool wear, and machining quality during diamond core drill grinding of 2.5D C/SiC composites.
• To analyze the effects of grinding angle, force, and thermal factors on machining outcomes.
• To clarify the tool wear stages and their correlation with processing parameters and machining quality.

Main Methods:

• Systematic experimental investigation of diamond core drill grinding.
• Analysis of material removal characteristics and hole wall machining quality under varying grinding angles and forces.
• Evaluation of thermal effects during the machining process.
• Characterization of tool wear evolution and its impact on machining quality.

Main Results:

• Diamond core drill wear progresses through three distinct stages: initial shedding, intermediate damage, and late-stage failure.
• Increased tool wear leads to significantly higher axial forces and grinding temperatures.
• Hole wall defects escalate from fiber fracture to complex failures like burrs and pull-out, with the most severe degradation at the hole exit.

Conclusions:

• The study provides a comprehensive understanding of the machining process for 2.5D C/SiC composites.
• Optimization of process parameters and tool design is crucial for enhancing machining quality.
• Results offer theoretical guidance and experimental basis for efficient and precise machining of high-performance composites.