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<p>Multi-materials have aeronautical, automotive or industrial machine components applications due to combining high specific stiffness and low weight from the composite with the ductility, impact resistance, and damage tolerance of the metal. In this work, 25.5&#xa0;mm-thick multi-materials with carbon fibre reinforced polymer and aluminium were drilled using four conventional twist drills with two different geometries, N-type and W-type, being the first two just polished (uncoated) and the latter two coated with physical vapour deposition tantalum carbide. Five different feed-rate values and four cutting speeds were used in a full factorial design to evaluate each parameter’s influence in the results, with emphasis on the cutting loads. Furthermore, the chip geometry, hole quality (dimensional analysis, internal roughness and presence of defects) and tool wear were also analysed resorting to an analysis of variance. From the combination of results, a feed of 0.15&#xa0;mm/rev and a cutting speed of 180&#xa0;m/min were the optimal parameters, leading a compromise between low thrust force and high material removal rates. The N-type and W-type coated drills had similar responses, with the first having 20.98% lower tool wear, but also 7.14% higher cutting loads and 11.95% higher hole roughness than the second. This means that the point angle and the helix angle changes did not make a significant difference in the tools’ performance. Future works include testing different drill geometry designs, like with chip-breaking grooves, in order to reduce the fibre pull-out and delamination defects observed in the holes and to perform a more efficient cut.</p>

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Performance evaluation of PVD TaC-coated tools in the drilling of thick CFRP/Al multi-materials

  • 期刊论文

  • 发表日期：

    2025年11月21日

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  • Rúben Costa,
  • Petr Kučera,
  • Miroslav Zetek,
  • Michal Povolný,
  • Tomáš Bakša,
  • Tiago Silva,
  • Daniel Figueiredo,
  • Abílio de Jesus,
  • Francisco Silva

摘要

Multi-materials have aeronautical, automotive or industrial machine components applications due to combining high specific stiffness and low weight from the composite with the ductility, impact resistance, and damage tolerance of the metal. In this work, 25.5 mm-thick multi-materials with carbon fibre reinforced polymer and aluminium were drilled using four conventional twist drills with two different geometries, N-type and W-type, being the first two just polished (uncoated) and the latter two coated with physical vapour deposition tantalum carbide. Five different feed-rate values and four cutting speeds were used in a full factorial design to evaluate each parameter’s influence in the results, with emphasis on the cutting loads. Furthermore, the chip geometry, hole quality (dimensional analysis, internal roughness and presence of defects) and tool wear were also analysed resorting to an analysis of variance. From the combination of results, a feed of 0.15 mm/rev and a cutting speed of 180 m/min were the optimal parameters, leading a compromise between low thrust force and high material removal rates. The N-type and W-type coated drills had similar responses, with the first having 20.98% lower tool wear, but also 7.14% higher cutting loads and 11.95% higher hole roughness than the second. This means that the point angle and the helix angle changes did not make a significant difference in the tools’ performance. Future works include testing different drill geometry designs, like with chip-breaking grooves, in order to reduce the fibre pull-out and delamination defects observed in the holes and to perform a more efficient cut.