Multiscale modelling and experimental analysis of ultrasonic-assisted drilling of GLARE fibre metal laminates

Muhammad Atif; Xibin Wang; Lijing Xie; Khaled Giasin; Yuan Ma; Chulin Jiang; Ugur Koklu; Jos Sinke

doi:10.1016/j.compositesa.2023.107962

Multiscale modelling and experimental analysis of ultrasonic-assisted drilling of GLARE fibre metal laminates

Muhammad Atif, Xibin Wang, Lijing Xie^*, Khaled Giasin, Yuan Ma, Chulin Jiang, Ugur Koklu, Jos Sinke

^*Corresponding author for this work

School of Mechanical Engineering

Research output: Contribution to journal › Article › peer-review

8 Citations (Scopus)

Abstract

This study aims to evaluate the effectiveness of Ultrasonic-assisted drilling (UAD) of Glass laminate aluminium reinforced epoxy (GLARE) at high cutting speeds (Spindle speeds: 3000–7500 rpm; feed rates 300–750 mm/min) by analysing the thrust force and hole quality metrics (surface roughness, hole size, and burr formations. The research also presents numerical modelling of FMLs under conventional and UAD regimes to predict thrust force using ABAQUS/SIMULIA. The thrust force and exit burrs were reduced by up to 40.83 % and 80 %, respectively. The surface roughness metrics (R_a and R_z) were slightly higher using UAD but remained within the desirable limits of surface roughness for machined aeronautical structures. The discrepancy between the simulation and experimental results was adequate and did not exceed 15 %. The current study shows that it is feasible to drill holes in GLARE using higher cutting parameters and maintain excellent hole quality, which means increased productivity and reduced costs.

Original language	English
Article number	107962
Journal	Composites Part A: Applied Science and Manufacturing
Volume	177
DOIs	https://doi.org/10.1016/j.compositesa.2023.107962
Publication status	Published - Feb 2024

Keywords

GLARE
Surface roughness
Thrust force
Ultrasonic assisted drilling

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10.1016/j.compositesa.2023.107962

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title = "Multiscale modelling and experimental analysis of ultrasonic-assisted drilling of GLARE fibre metal laminates",

abstract = "This study aims to evaluate the effectiveness of Ultrasonic-assisted drilling (UAD) of Glass laminate aluminium reinforced epoxy (GLARE) at high cutting speeds (Spindle speeds: 3000–7500 rpm; feed rates 300–750 mm/min) by analysing the thrust force and hole quality metrics (surface roughness, hole size, and burr formations. The research also presents numerical modelling of FMLs under conventional and UAD regimes to predict thrust force using ABAQUS/SIMULIA. The thrust force and exit burrs were reduced by up to 40.83 % and 80 %, respectively. The surface roughness metrics (Ra and Rz) were slightly higher using UAD but remained within the desirable limits of surface roughness for machined aeronautical structures. The discrepancy between the simulation and experimental results was adequate and did not exceed 15 %. The current study shows that it is feasible to drill holes in GLARE using higher cutting parameters and maintain excellent hole quality, which means increased productivity and reduced costs.",

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author = "Muhammad Atif and Xibin Wang and Lijing Xie and Khaled Giasin and Yuan Ma and Chulin Jiang and Ugur Koklu and Jos Sinke",

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AU - Atif, Muhammad

AU - Wang, Xibin

AU - Xie, Lijing

AU - Giasin, Khaled

AU - Ma, Yuan

AU - Jiang, Chulin

AU - Koklu, Ugur

AU - Sinke, Jos

PY - 2024/2

Y1 - 2024/2

N2 - This study aims to evaluate the effectiveness of Ultrasonic-assisted drilling (UAD) of Glass laminate aluminium reinforced epoxy (GLARE) at high cutting speeds (Spindle speeds: 3000–7500 rpm; feed rates 300–750 mm/min) by analysing the thrust force and hole quality metrics (surface roughness, hole size, and burr formations. The research also presents numerical modelling of FMLs under conventional and UAD regimes to predict thrust force using ABAQUS/SIMULIA. The thrust force and exit burrs were reduced by up to 40.83 % and 80 %, respectively. The surface roughness metrics (Ra and Rz) were slightly higher using UAD but remained within the desirable limits of surface roughness for machined aeronautical structures. The discrepancy between the simulation and experimental results was adequate and did not exceed 15 %. The current study shows that it is feasible to drill holes in GLARE using higher cutting parameters and maintain excellent hole quality, which means increased productivity and reduced costs.

AB - This study aims to evaluate the effectiveness of Ultrasonic-assisted drilling (UAD) of Glass laminate aluminium reinforced epoxy (GLARE) at high cutting speeds (Spindle speeds: 3000–7500 rpm; feed rates 300–750 mm/min) by analysing the thrust force and hole quality metrics (surface roughness, hole size, and burr formations. The research also presents numerical modelling of FMLs under conventional and UAD regimes to predict thrust force using ABAQUS/SIMULIA. The thrust force and exit burrs were reduced by up to 40.83 % and 80 %, respectively. The surface roughness metrics (Ra and Rz) were slightly higher using UAD but remained within the desirable limits of surface roughness for machined aeronautical structures. The discrepancy between the simulation and experimental results was adequate and did not exceed 15 %. The current study shows that it is feasible to drill holes in GLARE using higher cutting parameters and maintain excellent hole quality, which means increased productivity and reduced costs.

KW - GLARE

KW - Surface roughness

KW - Thrust force

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ER -

Multiscale modelling and experimental analysis of ultrasonic-assisted drilling of GLARE fibre metal laminates

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Keywords

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