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Investigation of the quality of Al-CFRP stacks when drilled using innovative approaches
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. Innovation and Technology, Hydro Extrusion Europe, Norsk Hydro (NOR). (KAMPT)ORCID iD: 0000-0002-0895-3303
Department of Industrial Engineering, University of Padova, Via Venezia 1, 35123 Padova (ITA).
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (KAMPT)
Department of Industrial Engineering, University of Padova, Via Venezia 1, 35123 Padova (ITA).
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2023 (English)In: CIRP Journal of Manufacturing Science and Technology, Vol. 43, p. 260-272Article in journal (Refereed) Published
Abstract [en]

The usage of metal/composite stacks such as those made of aluminum alloy (Al) and carbon fiber-reinforced polymer (CRFP) has recently increased in the aerospace industry thanks to their high strength-to-weight ratio. As drilling high-quality holes in metal/composite stacks is still a challenge, innovative machining processes, such as ultrasonic vibration-assisted drilling and cryogenic drilling, have gained increasing attention for the part quality they promise. The feasibility of using the synergistic ultrasonic cryogenic drilling approach on Al/CFRP stacks is investigated for the first time, and the influence of the aforementioned innovative drilling approaches at varying feed in relation to the hole quality declined in terms of geometrical accuracy, surface roughness, delamination, and surface defects evaluated. The cutting forces are acquired as well. The obtained results show that, at increasing feed, the hole quality drastically worsens, nevertheless, it improves when applying innovative drilling technologies with respect to the standard one. Overall, ultrasonic cryogenic drilling carried out at the lowest investigated feeds represents the best drilling scenario thanks to the simultaneous application of ultrasonic vibrations, which enhances the surface finish as a consequence of the decreased contact between the workpiece and tool, and cryogenic cooling, which makes the surfaces harder.

Place, publisher, year, edition, pages
2023. Vol. 43, p. 260-272
Keywords [en]
Al-CFRP stacks, Ultrasonic drilling, Cryogenic drilling, Hole accuracy, Delamination, Thrust force
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-19986DOI: 10.1016/j.cirpj.2023.04.011Scopus ID: 2-s2.0-85153475010OAI: oai:DiVA.org:hv-19986DiVA, id: diva2:1762132
Available from: 2023-06-02 Created: 2023-06-02 Last updated: 2023-06-02

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Tamil Alagan, NageswaranGustafsson, Andreas

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