Wear Evaluation of CVD Diamond Coated High-Performance Drilling Tools for Machining
of Carbon Fiber Rreinforced Plastics (CFRP)
1
Fraunhofer Institute for Production Systems and Design Technology (IPK), Berlin, Germany
2
Institute for Machine Tools and Factory Management (IWF) – TU Berlin, Germany
3
Institute for Materials Science and Technologies; Metallic Materials (MW) - TU Berlin, Germany
Submission date: 2019-12-04
Acceptance date: 2020-02-11
Online publication date: 2020-06-24
Publication date: 2020-06-24
Journal of Machine Engineering 2020;20(2):104-113
KEYWORDS
ABSTRACT
The application of carbon fiber reinforced plastics (CFRP) as lightweight construction material in aerospace industry is based on the favorable weight-to-strength ratio. But the inherent material properties pose great challenges for the tool- as well as the manufacturing industry. In terms of economic industrial production processes, the quality of machined workpieces exhibits poor reproducibility combined with high tool wear. For this purpose, high-performance drilling tools with different CVD diamond coatings and carbide substrates with varying binder content were tested and analyzed in order to assess coating adhesion and workpiece quality. Due to a reduction of cobalt binder within the tungsten carbide-based tool substrates, an increase of tool performance regarding borehole quantity until coating delamination is demonstrated. While the reduction of tool wear on
the rake face of the drilling tools can be correlated with the cutting tool performance, the online monitoring
of cutting forces does not explicitly identify damaged cutting tools during machining.
ACKNOWLEDGEMENTS
This publication is based on the results of the DFG UH 100/200-1 and DFG RE 688/71-1 research projects funded by the German Research Foundation (DFG).
REFERENCES (32)
1.
WITTEN E., SAUER M., KÜHNEL M., 2017, Composites Marktbericht 2017, https://www.avk-tv.de/files/20..._ avkccev__marktbericht_2017.pdf, (Accessed on November 5th 2019).
2.
M’SAOUBI R., AXINTE D., SOO S.L., NOBEL C., ATTIA H., KAPPMEYER G., ENGIN S., SIM W.M., 2015, High performance cutting of advanced aerospace alloys and composite materials, CIRP Ann. – Man. Technol., 64, 557–580.
3.
UHLMANN E., RICHARZ S., SAMMLER F., HUFSCHMIED R., 2016, High Speed Cutting of Carbon Fibre Reinforced Plastics, Proc. CIRP Manufacturing, 6, 113–123.
4.
WEGENER K., KUSTER F., WEIKERT L., WEISS L., STIRNIMANN J., 2016, Success Story Cutting, Proc. CIRP, 46, 512-524
5.
KARATAS M.E., GÖKKAYA H., 2018, A review on machinability of carbon fiber reinforced polymer (CFRP) and glass fiber reinforced polymer (GFRP) composite materials, Def. Tec., 14, 318–326.
6.
BYRNE G., AHEARNE E., COTTERELL M., MULLANY B., O’DONNELL G.E., SAMMLER F., 2016, High Performance Cutting (HPC) in the New Era of Digital Manufacturing – A Roadmap, Proc. CIRP, 46, 1–6.
7.
SORRENTINO L., TURCHETTA S., BELLINI C., 2018, A new method to reduce delaminations during drilling of FRP laminates by feed rate control, Comp. Struct., 186, 154–164.
8.
HALIM N.F.H.A., ASCROFT H., BARNES S., 2017, Analysis of Tool Wear, Cutting Forces, Surfaces Roughness and Machining Temperature During Finishing Operation of Ultrasonic Assisted Milling (UAM) of Carbon Fiber Reinforced Plastics (CFRP), Proc. Eng., 184, 185–191.
9.
UHLMANN E., SAMMLER F., RICHARZ S., HEITMÜLLER F., BILZ M., 2014, Machining of Carbon Fibre Reinforced Plastics, Proc. CIRP, 24, 19–24.
10.
WANG X., SHEN X., Zeng C., Sun F., 2018, Combined influences of tool shape and as-deposited diamond film on cutting performance of drills for CFRP machining, Surf. and Coat. Technol., 347, 390–397.
11.
RAMIREZ C., POULACHON G., ROSSI F., M’SAOUBI R., 2014, Tool Wear Monitoring and Hole Surface Quality During CFRP Drilling, Proc. CIRP, 13, 163–168.
12.
HINTZE W., CLAUSEN R., SCHÜTTE C., KROLL K., 2018, Evaluation of the total cutting force in drilling of CFRP: a novel experimental method for the analysis of the cutting mechanism, Prod. Eng., 12/3–4, 431–440.
13.
KUO C., WANG C., KO S., 2018, Wear behaviour of CVD diamond-coated tools in the drilling of woven CFRP composites, Wear, 398–399, 1–12.
14.
ZHANG J., YUAN Y., ZHANG J., 2018, Cutting Performance of Microcrystalline, Nanocrystalline and Dual-Layer Composite Diamond Coated Tools in Drilling Carbon Fiber Reinforced Plastics, Appl. Sci., 8, 1642.
15.
UHLMANN E., REIMERS W., SAMMLER F., 2012, Werkzeugauslegung zur Bearbeitung von Leichtbauwerkstoffen, wt online, 6, 217–229.
16.
ISMAIL S.O., DHAKAL H.N., POPOV I., BEAUGRAND J., 2016, Comprehensive study on machinability of sustainable and conventional fibre reinforced polymer composites, Eng. Sci. Technol. Int. J., 19/4, 2043–2052.
17.
BOBZIN K., 2017, High-performance coatings for cutting tools, CIRP J. Manuf. Sci. and Technol., 18, 1-9.
18.
SKORDARIS G., BOUZAKIS K.-D., KOTSANIS T., BOUMPAKIS A., STERGIOUDI F., CHRISTOFILOS D., LEMMER O., KÖLKER W., WODA M., 2019, Effect of the crystallinity of diamond coatings on cemented carbide inserts on their cutting performance in milling, CIRP Annals, 68/1, 65–68.
19.
MOHR M., CARON A., HERBECK-ENGEL P., 2014, Youngs modulus, fracture strength, and Poisson’s ration of nanocrystalline diamond flims, J. Appl. Phys., 116/12, doi.org/10.1063/1.4896729, (Accessed on November 5th 2019).
20.
SAMMLER F., 2015, Steigerung der Nutzungspotenziale von CVD-diamantbeschichteten Werkzeugen, Fraunhofer Verlag, Stuttgart.
21.
LI J., YU X., ZHANG Z., 2019, Exploring a diamond film to improve wear resistance of the hydraulic drilling impactor, Surf. and Coat. Technol., 360, 297–306.
22.
AHMED F., 2012, Deformation and damaging mechanisms in diamond thin films bonded to ductile substrates, University Nürnberg-Erlangen, http://nbn-resolving.de/urn:nb..., (Accessed on October 17th 2019).
23.
HINZMANN D., UHLMANN E., 2019, Einsatzverhalten von CVD-Diamantdünnschichtwerkzeugen, wt online, 7/8, 563–569.
24.
KLOCKE F., 2018, Fertigungsverfahren 1: Zerspanung mit geometrisch bestimmter Schneide, Springer Verlag, Wiesbaden.
25.
UHLMANN E., SAMMLER F., MEIXNER M., 2015, Analysis of residual stresses and wear mechanisms of HF-CVD diamond coated cemented carbide tools, J. Prod. Eng. Res. Develop., 9, 99–107.
26.
SKORDARIS G., BOUZAKIS K.-D., CHARALAMPOUS P., KOTSANIS T., BOUZAKIS E., LEMMER O., 2016, Effect of structure and residual stresses of diamond coated cemented carbide tools on the film adhesion and developed wear mechanisms in milling, CIRP Annals, 65/1, 101–104.
27.
SALGUEIREDO E., AMARAL M., ALMEIDA F.A., FERNANDES A.J.S., OLIVEIRA F.J., SILVA R.F., 2013, Mechanical performance upgrading of CVD diamond using the multilayer strategy, Surf. and Coat. Technol., 236, 380–387.
28.
UHLMANN E., KÖNIG J., SAMMLER F., RICHARZ S., 2014, Tribology of Treated and Coated Cutting Tool Surfaces, In: WANG Q.J., CHUNG Y.W. (eds), Encyclopedia of Tribology, Springer, Boston.
29.
GAYDAYCHUK A., ZENKIN S., LINNIK S., 2019, Influence of Al-Si-N interlayer on residual stress of CVD diamond coatings, Surf. and Coat. Technol., 357, 348–352.
30.
HOCHENG H., CHEN C.C., TSAO C.C., 2018, Prediction of critical thrust force for tubular composite in drilling-induced delamination by numerical and experimental analysis, Comp. Struct., 203, 5660–573.
31.
DIN EN ISO 6507-1, 2018, Metallic materials – Vickers hardness test – Part 1: Test method, International Organization for Standardization, Geneva.
32.
DIN EN ISO 3327, 2009, Hardmetals – Determination of transverse rupture strength, International Organization for Standardization, Geneva.
Share
RELATED ARTICLE
| eISSN: | 2391-8071 |
| ISSN: | 1895-7595 |
We process personal data collected when visiting the website. The function of obtaining information about users and their behavior is carried out by voluntarily entered information in forms and saving cookies in end devices. Data, including cookies, are used to provide services, improve the user experience and to analyze the traffic in accordance with the Privacy policy. Data are also collected and processed by Google Analytics tool (more).
You can change cookies settings in your browser. Restricted use of cookies in the browser configuration may affect some functionalities of the website.
You can change cookies settings in your browser. Restricted use of cookies in the browser configuration may affect some functionalities of the website.
