Cutting mechanism of drilling CFRP laminates and effects of ultrasonic torsional mode vibration cutting were investigated. CFRP laminates are made of carbon fiber reinforced/epoxy- resin matrix composite plies. Challenges in drilling CFRP laminates arise because of anisotropy due to carbon fiber orientation. Experimental works were performed to characterize major whole quality parameters and cutting characteristics encountered when conventional drilling CFRP laminates. Shallow craters of about 50-70μm depth were found at the particular position of inner surface in drilled hole and the reason of the growth of crater was investigated based on cutting mechanism of anisotropic composite material. In order to improve hole quality and tool life the specific drilling assisted by ultrasonic torsional mode vibration of 27 kHz was examined. The ultrasonic torsional mode vibration cutting was significantly effective to restrain the generation of the crater and also to elongate tool life about five times in drilling CFRP laminates.
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UPDATE:July 18, 2006