Cfrp
DRILLING OF HIGH-PERFORMANCE MATERIALS: EXPERIMENTAL, NUMERICAL, AND THEORETICAL INVESTIGATIONS by WEILONG CONG
B.S., Dalian Fisheries University, 2007
AN ABSTRACT OF A DISSERTATION submitted in partial fulfillment of the requirements for the degree
DOCTOR OF PHILOSOPHY
Department of Industrial & Manufacturing Systems Engineering College of Engineering
KANSAS STATE UNIVERSITY Manhattan, Kansas
2013
Abstract
High-performance materials, such as silicon, aerospace stainless steels, titanium alloys, and carbon fiber reinforced plastic (CFRP) composites, have a variety of engineering applications. However, they usually have poor machinability and are classified as hard-tomachine materials. Drilling is one of the important machining processes for these materials. Industries are always under tremendous pressure to meet the ever-increasing demand for lower cost and better quality of the products made from these high-performance materials. Rotary ultrasonic machining (RUM) is a non-traditional machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining. It is a relatively low-cost, environment-benign process that easily fits in the infrastructure of the traditional machining environment. Other advantages of this process include high hole accuracy, superior surface finish, high material removal rate, low tool pressure, and low tool wear rate. The goal of this research is to provide new knowledge of machining these high performance materials with RUM for further improvement in the machined hole quality and decrease in the machining cost. A thorough research in this dissertation has been conducted by experimental, numerical, and theoretical investigations on output variables, including cutting force, torque, surface roughness, tool wear, cutting temperature, material removal rate, edge chipping (for silicon), power consumption (for CFRP), delamination (for CFRP), and feasible regions (for dry machining of
B.S., Dalian Fisheries University, 2007
AN ABSTRACT OF A DISSERTATION submitted in partial fulfillment of the requirements for the degree
DOCTOR OF PHILOSOPHY
Department of Industrial & Manufacturing Systems Engineering College of Engineering
KANSAS STATE UNIVERSITY Manhattan, Kansas
2013
Abstract
High-performance materials, such as silicon, aerospace stainless steels, titanium alloys, and carbon fiber reinforced plastic (CFRP) composites, have a variety of engineering applications. However, they usually have poor machinability and are classified as hard-tomachine materials. Drilling is one of the important machining processes for these materials. Industries are always under tremendous pressure to meet the ever-increasing demand for lower cost and better quality of the products made from these high-performance materials. Rotary ultrasonic machining (RUM) is a non-traditional machining process that combines the material removal mechanisms of diamond grinding and ultrasonic machining. It is a relatively low-cost, environment-benign process that easily fits in the infrastructure of the traditional machining environment. Other advantages of this process include high hole accuracy, superior surface finish, high material removal rate, low tool pressure, and low tool wear rate. The goal of this research is to provide new knowledge of machining these high performance materials with RUM for further improvement in the machined hole quality and decrease in the machining cost. A thorough research in this dissertation has been conducted by experimental, numerical, and theoretical investigations on output variables, including cutting force, torque, surface roughness, tool wear, cutting temperature, material removal rate, edge chipping (for silicon), power consumption (for CFRP), delamination (for CFRP), and feasible regions (for dry machining of
References: [Boeing website] 787 Dreamliner Program Fact Sheet, available at: http://www.boeing.com/commercial/787family/programfacts.html, Accessed on June 24, 2012 448 [Kim and Lee, 2005] Kim G.W., and Lee K.Y., 2005, Critical thrust force at propagation of delamination zone due to drilling of FRP/metallic strips, Composite Structures, 69(2), pp 450 [Yagishita, 2008] Yagishita H., Comparing drilling and circular milling for hole making in bi-layer composite materials consisting of carbon fiber reinforced plastic (CFRP) laminates and titanium alloys, Transactions of NAMRI/SME, 36, pp