Sequential Laser-Mechanical Drilling of Thick Carbon Fibre Reinforced Polymer Composites (CFRP) for Industrial Applications

Carbon fibre reinforced polymer composites (CFRPs) can be costly to manufacture, but they are typically used anywhere a high strength-to-weight ratio and a high steadiness (rigidity) are needed in many industrial applications, particularly in aerospace. Drilling composites with a laser tends to be a feasible method since one of the composite phases is often in the form of a polymer, and polymers in general have a very high absorption coefficient for infrared radiation. The feasibility of sequential laser-mechanical drilling for a thick CFRP is discussed in this article. A 1 kW fibre laser was chosen as a pre-drilling instrument (or initial stage), and mechanical drilling was the final step. The sequential drilling method dropped the overall thrust and torque by an average of 61%, which greatly increased the productivity and reduced the mechanical stress on the cutting tool while also increasing the lifespan of the bit. The sequential drilling (i.e., laser 8 mm and mechanical 8 mm) for both drill bits (i.e., 2- and 3-flute uncoated tungsten carbide) and the laser pre-drilling techniques has demonstrated the highest delamination factor (S-FDSR) ratios. A new laser-mechanical sequence drilling technique is thus established, assessed, and tested when thick CFRP composites are drilled.

Automated summary

This article discusses the feasibility of sequential laser-mechanical drilling for thick CFRP composites. The method was found to reduce overall thrust and torque by an average of 61%, increasing productivity and extending the lifespan of cutting tools. The laser-mechanical sequence drilling technique showed the highest delamination factor ratios for both drill bits and laser pre-drilling techniques.