Vibration assisted drilling of CFRP/metal stacks at low frequencies and high amplitudes

Abstract

In many applications of automotive and aircraft industries the use of material combinations such as compound materials made from carbon fiber reinforced plastics (CFRP) and metal materials like steel, titanium or aluminum alloys is significantly increasing. For these industries, the lightweight and mechanical properties of the reinforced plastic materials gain more and more importance. When machining material combinations, a number of distinctive material related effects occur and hamper the straight-forward implementation of machining processes. These effects mainly derive from the distinctive chipping behavior of the material combination caused by the different material characteristics. Thus, the drilling process of CFRP/metal stacks is to be regarded as a challenging task due to the requirements of machining efficiency and quality aspects. In this regard, vibration assisted drilling at low frequencies but high amplitudes opens up significant opportunities for improvements of the machining processes. The feed rate is superimposed by a controlled harmonic motion in order to create an intermittent cutting state. The potential of vibration assisted drilling lies in the reduction of cutting forces and tool wear.