Numerical Investigation of the Hole Saw Tool Geometry Effects on Drilling of CFRP

Drilling in Carbon Fiber Reinforced Polymer (CFRP) composites is of paramount importance, especially in industries like aerospace that heavily rely on these advanced materials. The precision and integrity of the drilled holes play a vital role in determining the overall structural performance and reliability of composite components. This study presents a comprehensive numerical investigation into the effect of hole saw tool geometry and cutting parameters on the drilling of Carbon Fiber Reinforced Polymer (CFRP) composites. The analysis aims to optimize the drilling operation by varying the rake angle and the feed rate. To fulfil this, a finite element model is developed using Abaqus explicit software. The outcomes reveal that the rake angle has a negligible effect on the thrust force and the workpiece damage. In contrast, the feed rate significantly affects the thrust force, with a noticeable increase as the feed rate is raised. Finally, it can be observed that the workpiece damage is not influenced by the feed rate.