Investigation of the Effect of the Cutting Parameters on Cutting Forces and Tool Wear in the Stack Drilling of a Carbon Fibre-Reinforced Thermoplastic Matrix Composite and Aa7075

Abstract

This study investigate the stack drillability of unidirectional (UD) carbon fibre reinforced thermoplastic matrix PAEK/CF composite and AA7075 plate utilised in aerospace. The effects of the cutting parameters on cutting forces during the drilling process of thermoplastic matrix composites and aluminium materials were experimentally analysed. Drilling operations were carried out on a CNC Vertical Machining Centre under dry-cutting conditions. For three different drill types, three different cutting speeds, and feed rate combinations, a total of 810 holes were drilled in a full factorial experimental design with 30 replicates for each combination. The damage on the hole surfaces on the drilled composite was identified with an optical microscope. The numerical data were obtained in the composite testing laboratory and analysed using Minitab (R) 21.1 statistical software and transformed into graphs. The most suitable drill type and cutting parameters were determined for the drillability of composite with thermoplastic matrix and aluminium (AA7075) plates when stacked.