Influence of hole quality on fatigue life of drilled CFRP with the different ply orientation angle

In this study, the effect of drilling quality on fatigue life of UD, 0/90, and45 fiber angle carbon fiber reinforced plastics (CFRP) was investigated. CFRPs were drilled using WC, HSS, and Brad Spur tool types that have different geometries and materials at different feed rates of 0.05, 0.10, and 0.15 mm/rev, and at the different spindle speeds of 1000, 3000 and 5000 rev/min. Thrust forces were measured during the drilling of CFRPs, and surface roughnesses, deformation factors, and maximum tensile forces were measured after drilling operations. Thrust force, surface roughness, and deformation factor were evaluated in terms of drilling quality. The drilling parameters that cause the best, average, and worst drilling quality were determined. Then, fatigue behaviors of CFRPs drilled in these drilling parameters were investigated. Fatigue tests were carried out at %75, %80, %85, and %90 load ratios based on the lowest tensile force of the drilled samples. As a result of the study, it was determined that the thrust force, the deformation factor, and the surface roughness increased as the feed rate increased. However, the thrust force, the deformation factor, and the surface roughness decreased as the spindle speed increased. Besides, the best drilling quality was obtained from the drilling operation performed using WC tool type, at a spindle speed of 5000 rev/min and a feed rate of 0.05 mm/rev. The worst drilling quality was obtained from the drilling operation performed using Brad Spur tool type, at a spindle speed of 1000 rev/min and a feed rate of 0.15 mm/rev. With the decreasing drilling quality, a significant decrease occurred in the tensile force and fatigue life of CFRPs. The tensile load and fatigue life of CFRPs drilled in optimum drilling parameters were obtained higher. In the case of selecting the correct drilling parameters, it was observed that the reduction in fatigue life of CFRPs could be prevented ratios of %22-49.Graphical abstract

Automated summary

The study investigated the effect of drilling quality on the fatigue life of carbon fiber reinforced plastics (CFRP) with different fiber angles. It found that thrust force, deformation factor, and surface roughness increased with higher feed rates but decreased with higher spindle speeds. The best drilling quality was achieved with WC tool type at a spindle speed of 5000 rev/min and a feed rate of 0.05 mm/rev, while the worst quality was observed with Brad Spur tool type at a spindle speed of 1000 rev/min and a feed rate of 0.15 mm/rev. Decreasing drilling quality resulted in significant decreases in tensile force and fatigue life of CFRPs, with up to a 49% reduction.