Influence of drill geometry on hole quality in drilling hybrid carbon fibre reinforced polymer (HCFRP)

Balakrishnan, Ruvendran (2022) Influence of drill geometry on hole quality in drilling hybrid carbon fibre reinforced polymer (HCFRP). Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Drilling is one of the crucial processes in aerospace manufacturing industry due to the tight tolerances required for fasteners like rivets and bolts to attach certain parts for final assembly. Generally, these parts are made from Carbon Fibre Reinforced Plastic (CFRP) but recently more advanced material such as Hybrid Carbon Fibre Reinforced plastic (HCFRP) is utilized, and it promotes higher strength to weight ratio in aerospace application. However, one of the most difficult aspects of machining such polymers is the poor quality of the drilled holes which reduces the composite strength, resulting in component rejection during assembly. This study intends to investigate the influence of drill bit geometry on drilled hole quality and to the find optimal drill bit geometry in drilling HCFRP plates through simulation of finite element analysis (FEA) which was conducted using Ansys software. The design of experiment which is the surface response method is used to identify the best drill geometry by using different inputs of point angle and helix angle by using constant machining parameters. The output for this research is the delaminated area which includes the peel up delaminated area, the push down delaminated area and as well as the thrust force during drilling process. Based on the simulation result, the point angle of 120° and helix angle of 30° produces the most accurate hole with lesser peel up delaminated area and push down delamination area with the medium level of thrust force. Furthermore, the optimal drill geometry to drill HCFRP material is at the point angle of 135° and helix angle of 28.81°.

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