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Albuquerque, NM, United States

Ning F.D.,Texas Tech University | Cong W.L.,Texas Tech University | Pei Z.J.,Kansas State University | Treadwell C.,Sonic Mill
Ultrasonics | Year: 2016

Carbon fiber reinforced plastic (CFRP) composites have been intensively used in various industries due to their superior properties. In aircraft and aerospace industry, a large number of holes are required to be drilled into CFRP components at final stage for aircraft assembling. There are two major types of methods for hole making of CFRP composites in industry, twist drilling and its derived multi-points machining methods, and grinding and its related methods. The first type of methods are commonly used in hole making of CFRP composites. However, in recent years, rotary ultrasonic machining (RUM), a hybrid machining process combining ultrasonic machining and grinding, has also been successfully used in drilling of CFRP composites. It has been shown that RUM is superior to twist drilling in many aspects. However, there are no reported investigations on comparisons between RUM and grinding in drilling of CFRP. In this paper, these two drilling methods are compared in five aspects, including cutting force, torque, surface roughness, hole diameter, and material removal rate. © 2015 Elsevier B.V. All rights reserved. Source


Cong W.L.,Kansas State University | Pei Z.J.,Kansas State University | Deines T.W.,Kansas State University | Liu D.F.,Central South University | Treadwell C.,Sonic Mill
Composites Part B: Engineering | Year: 2013

Rotary ultrasonic machining (RUM) has been successfully used to drill Ti (titanium and its alloy), CFRP, and CFRP/Ti stacks. In all studies on RUM reported in the literature, feedrate was fixed during each experimental test. It has been shown that low feedrate should be used for RUM of Ti, but RUM of CFRP could be done using feedrate 10 times higher. This paper, for the first time, reports a study on RUM of CFRP/Ti stacks using variable feedrate (high feedrate for CFRP and low feedrate for Ti). It also makes comparisons on RUM of CFRP/Ti stacks using fixed and variable feedrate. © 2013 Elsevier Ltd. All rights reserved. Source


Cong W.L.,Texas Tech University | Cong W.L.,Kansas State University | Pei Z.J.,Kansas State University | Treadwell C.,Sonic Mill
Ultrasonics | Year: 2014

Reported drilling methods for CFRP/Ti stacks include twist drilling, end milling, core grinding, and their derived methods. The literature does not have any report on drilling of CFRP/Ti stacks using rotary ultrasonic machining (RUM). This paper, for the first time, reports a study on drilling of CFRP/Ti stacks using RUM. It also compares results on drilling of CFRP/Ti stacks using RUM with reported results on drilling of CFRP/Ti stacks using other methods. When drilling CFRP/Ti stacks using RUM, cutting force, torque, and CFRP surface roughness were lower, hole size variation was smaller, CFRP groove depth was smaller, tool life was longer, and there was no obvious Ti exit burr and CFRP entrance delamination. Ti surface roughness when drilling of CFRP/Ti stacks using RUM was about the same as those when using other methods. © 2014 Elsevier B.V. All rights reserved. Source


Cong W.L.,Kansas State University | Pei Z.J.,Kansas State University | Feng Q.,Kansas State University | Deines T.W.,Kansas State University | Treadwell C.,Sonic Mill
Journal of Reinforced Plastics and Composites | Year: 2012

Drilling is involved in many applications of carbon fiber-reinforced plastic composite. Twist drilling is widely used in industry. Rotary ultrasonic machining has been successfully tested to drill holes in carbon fiber-reinforced plastic. However, there are no reports on comparisons between rotary ultrasonic machining and twist drilling of carbon fiber-reinforced plastic. This paper compares rotary ultrasonic machining and twist drilling of carbon fiber-reinforced plastic in six aspects (cutting force, torque, surface roughness, delamination, tool life, and material remove rate). Experimental results show that rotary ultrasonic machining is superior in almost all these aspects. © 2012 The Author(s). Source


Cong W.L.,Kansas State University | Feng Q.,Kansas State University | Pei Z.J.,Kansas State University | Deines T.W.,Kansas State University | Treadwell C.,Sonic Mill
Journal of Composite Materials | Year: 2012

Drilling is involved in many applications of carbon fiber-reinforced plastic (CFRP) composites. Rotary ultrasonic machining (RUM) has been successfully employed to drill holes in CFRP using either cutting fluid or cold air as coolant. However, there are no reported studies to compare the results in RUM of CFRP using these two types of coolant. This article, for the first time, presents an experimental study to compare cutting force, torque, surface roughness, burning of machined surface, and tool wear in RUM of CFRP using these two types of coolant. This study will result in knowledge about machining conditions under which it is feasible to use cold air instead of cutting fluid and differences in machined hole quality produced using cold air vs. cutting fluid. © The Author(s) 2011 Reprints and permissions: sagepub.co.uk/ journalsPermissions.nav. Source

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