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<p>To meet the performance, lightweight, and environmental requirements of aerospace vehicles, CF/PEKK composites are increasingly adopted in the aerospace sector. Ensuring high-quality hole machining is crucial to improve joint connection strength while also balancing machining costs, where tool life plays a vital role. This study examines drill bit wear during CF/PEKK drilling through experimental research, comparing ultrasonic vibration-assisted drilling (UVAD) and conventional drilling (CD), as well as different drill material types. The results demonstrate that UVAD significantly reduces drill bit wear, with the trailing edge’s average wear width 25.9% lower than that of CD. Moreover, higher feed rates and spindle speeds in UVAD further decrease wear, enhancing tool life. Carbide tools or tools with superior hardness and wear resistance are recommended for improved efficiency and hole quality. This work provides a practical technical foundation for high-quality, efficient, and cost-effective CF/PEKK machining, offering valuable insights for aerospace and other material-processing applications.</p>

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An experimental study on drill bit wear and hole quality in ultrasonic vibration-assisted drilling of carbon fiber-reinforced polyetherketoneketone composites

  • 期刊论文

  • 发表日期：

    2025年6月17日

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  • Meihua Zhang,
  • Nan Wu,
  • Liqiang Zhang,
  • Yaqi Zhang,
  • Gang Liu

摘要

To meet the performance, lightweight, and environmental requirements of aerospace vehicles, CF/PEKK composites are increasingly adopted in the aerospace sector. Ensuring high-quality hole machining is crucial to improve joint connection strength while also balancing machining costs, where tool life plays a vital role. This study examines drill bit wear during CF/PEKK drilling through experimental research, comparing ultrasonic vibration-assisted drilling (UVAD) and conventional drilling (CD), as well as different drill material types. The results demonstrate that UVAD significantly reduces drill bit wear, with the trailing edge’s average wear width 25.9% lower than that of CD. Moreover, higher feed rates and spindle speeds in UVAD further decrease wear, enhancing tool life. Carbide tools or tools with superior hardness and wear resistance are recommended for improved efficiency and hole quality. This work provides a practical technical foundation for high-quality, efficient, and cost-effective CF/PEKK machining, offering valuable insights for aerospace and other material-processing applications.