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<p>Carbon fiber-reinforced polymer (CFRP) has become increasingly important in aerospace applications due to its exceptional mechanical properties. However, its inherent hardness and brittleness pose significant challenges during machining, often resulting in poor quality and reduced tool life, particularly in drilling operations. To address these issues, this study proposes a novel design for a low-frequency vibration-assisted drilling (LF-VAD) device aimed at enhancing the drilling performance of CFRP materials. The LF-VAD device was designed based on the principles of the cam mechanism and comprises key components, including an amplitude lock key, stopper block, roller cage, and sinusoidal cam, all working in unison to provide precise control of axial low-frequency vibrations and optimize energy transfer during the drilling process. The fabrication of the LF-VAD device involved precise manufacturing techniques, with finite element analysis (FEA) conducted during the design phase to ensure its efficiency and durability. This process resulted in an optimized device capable of delivering stable vibration performance, effectively minimizing tool wear while improving the quality of drilled holes. Drilling experiments using the LF-VAD device were conducted on CFRP materials following an orthogonal experimental design. These experiments demonstrated a significant reduction in delamination and improved chip removal compared to conventional drilling techniques. Furthermore, the results highlighted that maintaining the vibration amplitude between 10 and 20&#xa0;µm yielded optimal hole quality. This study underscores the effectiveness of the LF-VAD device in addressing the machining challenges of CFRP, offering a promising solution for improving the material's performance in advanced aerospace applications.</p> Graphical abstract <p></p>

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Design of low-frequency vibration-assisted drilling tool and its machining performance on CFRP

  • 期刊论文

  • 发表日期：

    2025年10月30日

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  • Muhammad Hamed,
  • Chen Zhang,
  • Muhammad Saleem,
  • M. D. Musanur Islam,
  • Rubo Wu,
  • Chi Zhang

摘要

Carbon fiber-reinforced polymer (CFRP) has become increasingly important in aerospace applications due to its exceptional mechanical properties. However, its inherent hardness and brittleness pose significant challenges during machining, often resulting in poor quality and reduced tool life, particularly in drilling operations. To address these issues, this study proposes a novel design for a low-frequency vibration-assisted drilling (LF-VAD) device aimed at enhancing the drilling performance of CFRP materials. The LF-VAD device was designed based on the principles of the cam mechanism and comprises key components, including an amplitude lock key, stopper block, roller cage, and sinusoidal cam, all working in unison to provide precise control of axial low-frequency vibrations and optimize energy transfer during the drilling process. The fabrication of the LF-VAD device involved precise manufacturing techniques, with finite element analysis (FEA) conducted during the design phase to ensure its efficiency and durability. This process resulted in an optimized device capable of delivering stable vibration performance, effectively minimizing tool wear while improving the quality of drilled holes. Drilling experiments using the LF-VAD device were conducted on CFRP materials following an orthogonal experimental design. These experiments demonstrated a significant reduction in delamination and improved chip removal compared to conventional drilling techniques. Furthermore, the results highlighted that maintaining the vibration amplitude between 10 and 20 µm yielded optimal hole quality. This study underscores the effectiveness of the LF-VAD device in addressing the machining challenges of CFRP, offering a promising solution for improving the material's performance in advanced aerospace applications.

Graphical abstract