碳纤维增强树脂基复合材料钻孔技术研究进展
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摘要
碳纤维增强树脂基复合材料(CFRP)因性能优异,在航空航天领域的应用越加广泛,对其二次成形加工质量要求越来越高。本文综述了近年来碳纤维复合材料切削机理与钻孔工艺方法、刀具磨损机理、钻孔缺陷和损伤产生机理及其控制等方面的研究现状和进展,分析了存在的问题和新的挑战,并对CFRP钻孔技术的研究进行了展望。
Carbon fiber reinforced plastics( CFRP) has been widely used in aerospace industry due to its excellent properties,and its secondary forming quality is required to be higher and higher. In this paper,the research status and progress of cutting mechanism and drilling technology,tool wear mechanism,drilling defect and damage mechanism and control of carbon fiber reinforced plastics in recent years are reviewed,the existing problems and new challenges are analyzed. Finally,the prospect of CFRP drilling technology is discussed.
Carbon fiber reinforced plastics( CFRP) has been widely used in aerospace industry due to its excellent properties,and its secondary forming quality is required to be higher and higher. In this paper,the research status and progress of cutting mechanism and drilling technology,tool wear mechanism,drilling defect and damage mechanism and control of carbon fiber reinforced plastics in recent years are reviewed,the existing problems and new challenges are analyzed. Finally,the prospect of CFRP drilling technology is discussed.
引文
[1]陈燕,葛恩德,傅玉灿,等.碳纤维增强树脂基复合材料制孔技术研究现状与展望[J].复合材料学报,2015,32(2):301-306.
[2]Liu D F,Tang Y J,Cong W L.A review of mechanical drilling for composite laminates[J].Composite Structures,2012,94:1265-1279.
[3]Guu Y H,Hocheng H,Tai N H,et al.Effect of electrical discharge machining on the characteristics of carbon fiber reinforced carbon composites[J].Journal of Materials Science,2001,36:2037-2043.
[4]Trevor M Young.Impact of Nd-YAG laser drilling on the fatigue characteristics of APC-2A-AS4 thermoplastic composite material[J].Journal of Thermoplastic Composite Materials,2008,21:543-555.
[5]Hocheng H,Tai N H,Liu C S.Assessment of ultrasonic drilling of C/Si C composite material[J].Composites Part A:Applied Science and Manufacturing,2000,31:133-142.
[6]Karnik S R,Gaitonde V N,Campos Rubio J,et al.Delamination analysis in high speed drilling of carbon fiber reinforced plastics(CFRP)using artificial neural network model[J].Materials&Design,2008,29(9):1768-1776.
[7]Tsao C C.Effect of pilot hole on thrust force by saw drill[J].International Journal of Machine Tools and Manufacture,2007,47(14):2172-2176.
[8]Koenig W,Wulf C,Grass P,et al.Machining of fibre reinforced plasitics[J].CIRP Annals Manufacturing Technology,1985,34(2):537-548.
[9]Wern C W,Ramulu M,Shukla A.Investigation of stresses in the orthogonal cutting of fiber-reinforced plastics[J].Experimental Mechanics,1996,36(1):33-41.
[10]Voss R,Henerichs M,Kustera F,et al.Chip root analysis after machining carbon fiber reinforced plastics(CFRP)at different fiber orientations[J].Procedia CIRP,2014,14:217-222.
[11]Niu B,Su Y L,Yang R,et al.Micro-macro-mechanical model and material removal mechanism of machining carbon fiber reinforced polymer[J].International Journal of Machine Tools&Manufacture,2016,111:43-54.
[12]陈明,邱坤贤,秦声,等.高强度碳纤维增强复合材料层合板的钻削制孔过程及其缺陷形成分析[J].南京航空航天大学学报,2014,46(5):667-674.
[13]Calzada K A,Kapoor S G,Devor R E,et al.Modeling and interpretation of fiber orientation-based failure mechanisms in machining of carbon fiber-reinforced polymer composites[J].Journal of Manufacturing Processes,2012,14(2):141-149.
[14]Phadnis V A,Makhdum F,Roy A,et al.Drilling in carbon/epoxy composites:experiment implemention[J].Composites Part A:Applied Science and Manufacturing,2013,47:41-51.
[15]Isbilir O,Ghassemieh E.Numerical investigation of the effects of drill geometry on drilling induced delamination of carbon fiber reinforced composites[J].Composite Structures,2013,105:126-133.
[16]Isbilir O,Ghassemieh E.Finite element analysis of drilling of carbon fiber reinforced composites[J].Applied Composite Materials,2012,19(3-4):637-656.
[17]Chinmaya R D,Yung C S.Modeling of machining of composite materials:a review[J].International Journal of Machine Tools&Manufacture,2012,57:102-121.
[18]杨强,解维华,孟松鹤,等.复合材料多尺度分析方法与典型元件拉伸损伤模拟[J].复合材料学报,2015,32(3):617-624.
[19]Rao G V G,Mahajan P,Bhatnagar N.Micro-mechanical modeling of machining of FRP composites:cutting force analysis[J].Composites Science and Technology,2007,67:579-593.
[20]Rao G V G,Mahajan P,Bhatnagar N.Machining of UD-GFRP composites chip formation mechanism[J].Composites Science and Technology,2007,67:2271-2281.
[21]Shiari B,Miller R E,Klug D D.Multi-scale simulation of material removal processes at the nanoscale[J].Journal of the Mechanics and Physics of Solids,2007,55:2384-2405.
[22]Sun X Z,Cheng K.Multi-scale simulation of the nano-metric cutting process[J].Int J Adv Manuf Technol,2010,47:891-901.
[23]范镜泓.材料变形与破坏的多尺度分析[M].北京:科学出版社,2008.
[24]郑晓霞,郑锡涛,缑林虎.多尺度方法在复合材料力学分析中的研究进展[J].力学进展,2010,40(1):41-55.
[25]Stone R,Krishnamurthy K.A neural network thrust force controller to minimize delamination during drilling of graphite-epoxy laminates[J].Int.J.Mach.Tools Manuf.,1996,36:985-1003.
[26]Tsao C C,Hocheng H.Parametric study on thrust force of core drill[J].Journal of Materials Processing Technology,2007(192-193):37-40.
[27]Tsao C C,Chiu Y C.Evaluation of drilling parameters on thrust force in drilling carbon fiber reinforced plastic(CFRP)composite laminates using compound core-special drills[J].International Journal of Machine Tools&Manufacture,2011,51:740-744.
[28]刘洋,李鹏南,陈明,等.双锋角钻头钻削碳纤维增强树脂基复合材料研究[J].宇航材料工艺,2015,45(6):53-59.
[29]Jain S,Yang D C H.Delamination free drilling of composite laminates[J].ASME J Eng Ind,1994,116:475-481.
[30]鲍永杰,高航,李凤全.电镀金刚石钻头钻削碳纤维复合材料研究[J].金刚石与磨料磨具工程,2009(3):38-42.
[31]徐九华,牟娟,陈燕,等.钎焊金刚石套料钻CFRP制孔研究[J].南京航空航天大学学报,2012,44(5):747-753.
[32]贾振元,何春伶,付饶,等.基于CFRP层合板钻削轴向力时变曲线的钻头几何形状分析[J].复合材料学报,2016,33(12):2757-2765.
[33]Hocheng H,Tsao C C.Effects of special drill bits on drilling induced delamination of composite materials[J].International Journal of Machine Tools and Manufacture,2006,46(12-13):1403-1416.
[34]Feito N,Diaz-álvarez J,López-Puente J,et al.Numerical analysis of the influence of tool wear and special cutting geometry when drilling woven CFRPs[J].Compos Struct,2016,138:285-294.
[35]Feito N,Díaz-álvarez J,Lopez-Puente J,et al.Experimental and numerical analysis of step drill bit performance when drilling woven CFRPs[J/OL].Compos Struct 2017.https://doi.org/10.1016/j.compstruct.2017.10.061.
[36]Xinyi Qiu,Pengnan Li,Qiulin Niu,et al.Influence of machining parameters and tool structure on cutting forceand hole wall damage in drilling CFRP with stepped drills[J].The International Journal of Advanced Manufacturing Technology,2018,97:857-865.
[37]Qiu X,Li P,Li C,et al.Study on chisel edge drilling behavior and step drill structure on delamination in drilling CFRP[J].Composite Structures,2018,203:404-413.
[38]Zhenyuan Jia,Rao Fu,Bin Niu,et al.Novel drill structure for damage reduction in drilling CFRP composites[J].International Journal of Machine Tools&Manufacture,2016(110):55-65.
[39]Xinyi Qiu,Pengnan Li,Changping Li,et al.New compound drill bit for damage reduction in drilling CFRP[J/OL].International Journal of Precision Engineering and Manufacturing-Green Technology,Publishedonline:December 2018.DOI:10.1007/s40684-019-00026-3.
[40]Tsao C C,Hocheng H.Effect of eccentricity of twist drill and candle stick drill on delamination in drilling composite materials[J].International Journal of Machine Tools and Manufacture,2005,45(2):125-130.
[41]Paulo Davim J,Pedro Reis.Drilling carbon fiber reinforced plastics manufactured by autoclave experimental and statistical study[J].Materials and Design,2003,24:315-324.
[42]Bonnet C,Poulachon G,Rech J,et al.CFRP drilling:Fundamental study of local feed force and consequences on hole exit damage[J].International Journal of Machine Tools and Manufacture,2015,94:57-64.
[43]Girot F,Dauc F,Gutiérrez-Orrantiab M E.New analytical model for delamination of CFRP during drilling[J].Journal of Materials Processing Technology,2016,10.
[44]张厚江,陈五一,陈鼎昌.碳纤维复合材料(CFRP)钻孔出口缺陷的研究[J].机械工程学报,2004(7):153-155.
[45]孙路华,全燕鸣,钟文旺.碳纤维复合材料高速钻削力的研究[J].纤维复合材料,2005(4):30-32,38.
[46]鲍永杰,高航,马海龙,等.单向C/E复合材料磨削制孔温度场模型的研究[J].机械工程学报,2012,48(1):169-176.
[47]Li N Y,Li Y G,Zhou J,et al.Drilling delamination and thermal damage of carbon nanotube carbon[J].International Journal of Machine Tools and Manufacture,2015,97:11-17.
[48]Munoz V,Vales B,Perrin M,et al.Damage detection in CFRP by coupling acoustic emission and infrared thermography[J].Composites Part B,2016,85:68-75.
[2]Liu D F,Tang Y J,Cong W L.A review of mechanical drilling for composite laminates[J].Composite Structures,2012,94:1265-1279.
[3]Guu Y H,Hocheng H,Tai N H,et al.Effect of electrical discharge machining on the characteristics of carbon fiber reinforced carbon composites[J].Journal of Materials Science,2001,36:2037-2043.
[4]Trevor M Young.Impact of Nd-YAG laser drilling on the fatigue characteristics of APC-2A-AS4 thermoplastic composite material[J].Journal of Thermoplastic Composite Materials,2008,21:543-555.
[5]Hocheng H,Tai N H,Liu C S.Assessment of ultrasonic drilling of C/Si C composite material[J].Composites Part A:Applied Science and Manufacturing,2000,31:133-142.
[6]Karnik S R,Gaitonde V N,Campos Rubio J,et al.Delamination analysis in high speed drilling of carbon fiber reinforced plastics(CFRP)using artificial neural network model[J].Materials&Design,2008,29(9):1768-1776.
[7]Tsao C C.Effect of pilot hole on thrust force by saw drill[J].International Journal of Machine Tools and Manufacture,2007,47(14):2172-2176.
[8]Koenig W,Wulf C,Grass P,et al.Machining of fibre reinforced plasitics[J].CIRP Annals Manufacturing Technology,1985,34(2):537-548.
[9]Wern C W,Ramulu M,Shukla A.Investigation of stresses in the orthogonal cutting of fiber-reinforced plastics[J].Experimental Mechanics,1996,36(1):33-41.
[10]Voss R,Henerichs M,Kustera F,et al.Chip root analysis after machining carbon fiber reinforced plastics(CFRP)at different fiber orientations[J].Procedia CIRP,2014,14:217-222.
[11]Niu B,Su Y L,Yang R,et al.Micro-macro-mechanical model and material removal mechanism of machining carbon fiber reinforced polymer[J].International Journal of Machine Tools&Manufacture,2016,111:43-54.
[12]陈明,邱坤贤,秦声,等.高强度碳纤维增强复合材料层合板的钻削制孔过程及其缺陷形成分析[J].南京航空航天大学学报,2014,46(5):667-674.
[13]Calzada K A,Kapoor S G,Devor R E,et al.Modeling and interpretation of fiber orientation-based failure mechanisms in machining of carbon fiber-reinforced polymer composites[J].Journal of Manufacturing Processes,2012,14(2):141-149.
[14]Phadnis V A,Makhdum F,Roy A,et al.Drilling in carbon/epoxy composites:experiment implemention[J].Composites Part A:Applied Science and Manufacturing,2013,47:41-51.
[15]Isbilir O,Ghassemieh E.Numerical investigation of the effects of drill geometry on drilling induced delamination of carbon fiber reinforced composites[J].Composite Structures,2013,105:126-133.
[16]Isbilir O,Ghassemieh E.Finite element analysis of drilling of carbon fiber reinforced composites[J].Applied Composite Materials,2012,19(3-4):637-656.
[17]Chinmaya R D,Yung C S.Modeling of machining of composite materials:a review[J].International Journal of Machine Tools&Manufacture,2012,57:102-121.
[18]杨强,解维华,孟松鹤,等.复合材料多尺度分析方法与典型元件拉伸损伤模拟[J].复合材料学报,2015,32(3):617-624.
[19]Rao G V G,Mahajan P,Bhatnagar N.Micro-mechanical modeling of machining of FRP composites:cutting force analysis[J].Composites Science and Technology,2007,67:579-593.
[20]Rao G V G,Mahajan P,Bhatnagar N.Machining of UD-GFRP composites chip formation mechanism[J].Composites Science and Technology,2007,67:2271-2281.
[21]Shiari B,Miller R E,Klug D D.Multi-scale simulation of material removal processes at the nanoscale[J].Journal of the Mechanics and Physics of Solids,2007,55:2384-2405.
[22]Sun X Z,Cheng K.Multi-scale simulation of the nano-metric cutting process[J].Int J Adv Manuf Technol,2010,47:891-901.
[23]范镜泓.材料变形与破坏的多尺度分析[M].北京:科学出版社,2008.
[24]郑晓霞,郑锡涛,缑林虎.多尺度方法在复合材料力学分析中的研究进展[J].力学进展,2010,40(1):41-55.
[25]Stone R,Krishnamurthy K.A neural network thrust force controller to minimize delamination during drilling of graphite-epoxy laminates[J].Int.J.Mach.Tools Manuf.,1996,36:985-1003.
[26]Tsao C C,Hocheng H.Parametric study on thrust force of core drill[J].Journal of Materials Processing Technology,2007(192-193):37-40.
[27]Tsao C C,Chiu Y C.Evaluation of drilling parameters on thrust force in drilling carbon fiber reinforced plastic(CFRP)composite laminates using compound core-special drills[J].International Journal of Machine Tools&Manufacture,2011,51:740-744.
[28]刘洋,李鹏南,陈明,等.双锋角钻头钻削碳纤维增强树脂基复合材料研究[J].宇航材料工艺,2015,45(6):53-59.
[29]Jain S,Yang D C H.Delamination free drilling of composite laminates[J].ASME J Eng Ind,1994,116:475-481.
[30]鲍永杰,高航,李凤全.电镀金刚石钻头钻削碳纤维复合材料研究[J].金刚石与磨料磨具工程,2009(3):38-42.
[31]徐九华,牟娟,陈燕,等.钎焊金刚石套料钻CFRP制孔研究[J].南京航空航天大学学报,2012,44(5):747-753.
[32]贾振元,何春伶,付饶,等.基于CFRP层合板钻削轴向力时变曲线的钻头几何形状分析[J].复合材料学报,2016,33(12):2757-2765.
[33]Hocheng H,Tsao C C.Effects of special drill bits on drilling induced delamination of composite materials[J].International Journal of Machine Tools and Manufacture,2006,46(12-13):1403-1416.
[34]Feito N,Diaz-álvarez J,López-Puente J,et al.Numerical analysis of the influence of tool wear and special cutting geometry when drilling woven CFRPs[J].Compos Struct,2016,138:285-294.
[35]Feito N,Díaz-álvarez J,Lopez-Puente J,et al.Experimental and numerical analysis of step drill bit performance when drilling woven CFRPs[J/OL].Compos Struct 2017.https://doi.org/10.1016/j.compstruct.2017.10.061.
[36]Xinyi Qiu,Pengnan Li,Qiulin Niu,et al.Influence of machining parameters and tool structure on cutting forceand hole wall damage in drilling CFRP with stepped drills[J].The International Journal of Advanced Manufacturing Technology,2018,97:857-865.
[37]Qiu X,Li P,Li C,et al.Study on chisel edge drilling behavior and step drill structure on delamination in drilling CFRP[J].Composite Structures,2018,203:404-413.
[38]Zhenyuan Jia,Rao Fu,Bin Niu,et al.Novel drill structure for damage reduction in drilling CFRP composites[J].International Journal of Machine Tools&Manufacture,2016(110):55-65.
[39]Xinyi Qiu,Pengnan Li,Changping Li,et al.New compound drill bit for damage reduction in drilling CFRP[J/OL].International Journal of Precision Engineering and Manufacturing-Green Technology,Publishedonline:December 2018.DOI:10.1007/s40684-019-00026-3.
[40]Tsao C C,Hocheng H.Effect of eccentricity of twist drill and candle stick drill on delamination in drilling composite materials[J].International Journal of Machine Tools and Manufacture,2005,45(2):125-130.
[41]Paulo Davim J,Pedro Reis.Drilling carbon fiber reinforced plastics manufactured by autoclave experimental and statistical study[J].Materials and Design,2003,24:315-324.
[42]Bonnet C,Poulachon G,Rech J,et al.CFRP drilling:Fundamental study of local feed force and consequences on hole exit damage[J].International Journal of Machine Tools and Manufacture,2015,94:57-64.
[43]Girot F,Dauc F,Gutiérrez-Orrantiab M E.New analytical model for delamination of CFRP during drilling[J].Journal of Materials Processing Technology,2016,10.
[44]张厚江,陈五一,陈鼎昌.碳纤维复合材料(CFRP)钻孔出口缺陷的研究[J].机械工程学报,2004(7):153-155.
[45]孙路华,全燕鸣,钟文旺.碳纤维复合材料高速钻削力的研究[J].纤维复合材料,2005(4):30-32,38.
[46]鲍永杰,高航,马海龙,等.单向C/E复合材料磨削制孔温度场模型的研究[J].机械工程学报,2012,48(1):169-176.
[47]Li N Y,Li Y G,Zhou J,et al.Drilling delamination and thermal damage of carbon nanotube carbon[J].International Journal of Machine Tools and Manufacture,2015,97:11-17.
[48]Munoz V,Vales B,Perrin M,et al.Damage detection in CFRP by coupling acoustic emission and infrared thermography[J].Composites Part B,2016,85:68-75.