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Carbon Fiber Reinforced Plastic (CFRP) and Titanium Alloy (Ti6Al4V) stack, extensively used in aerospace structural components are assembled by fasteners and the holes are made using drilling process. Drilling of stack in one shot is a complicated process due to dissimilarity in the material properties. It is vital to have optimal machining condition and tool geometry for better hole quality and tool life. In this study the tool wear and hole quality were analysed by experimental analysis using three modified twist drills and online tool condition monitoring using Acoustics Emission (AE) sensor. Helix angle and point angle influence tool performance and cutting force. It was found that a tool geometry (TG1) with high helix angle of 35°with low point angle 130° results in reduction in thrust force of 150-500 N range but the TG2 also perform almost similar to TG1, but when compared with the AErms voltage generated during drilling it was found that progressive rise in voltage in TG1 is less with respect to TG2 which can be attributed to tool life. In process wear monitoring was done using crest factor as monitoring index. AErms voltage were measured and correlated with the performance of the drills.
Light weight and high strength materials like carbon fiber reinforce plastics (CFRP), Titanium alloys (Ti) and stacks (CFRP/Ti, CFRP/Al, CFRP/Al/Ti) are being extensively used in commercial aircraft. Drilling process on the aircraft components was carried out to facilitate the assembly process. Drilling operations are made under dry condition which leads to tool wear and poor hole quality. In this paper study on drilling of CFRP/Ti6Al4V stacks under minimum quantity lubrication (MQL) using LRT 30 oil with varying flow rate, spindle speed and feed rate have been carried out using three modified drill tool made of solid carbide (K 20) coated with TiAlN. The recital of the tools were evaluated based on hole quality, burr height, thrust force, chip formation and tool wear. It was found that TG1 tool performance was better by producing minimum burr height while drilling Ti. TG2 recital was better by producing minimum force and better hole quality.