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<p>The determination of optimal drilling parameters for Braided Carbon Fiber Reinforced Polyether Ether Ketone (BCF/PEEK) composites is critical for minimizing damage mechanisms such as tearing and delamination, while enhancing tensile strength and extending structural service life. This study proposes a multi-objective optimization method to reduce damage and improve hole quality in BCF/PEEK composites, focusing on the interaction of thermal and mechanical factors. A novel BCF/PEEK composite was fabricated using an advanced molding process, and its mechanical properties were systematically characterized. Three specialized bits were designed and manufactured for BCF/PEEK drilling. A multi-scale thermo-mechanical drilling finite element (FE) model for different drill bits was developed based on a modified micro-mechanics of failure criterion, and the corresponding comprehensive monitoring drilling experimental platform was established to validate the accuracy of the multi-scale FE model. Orthogonal simulation experiments were employed to evaluate the influence of drill bit types and process parameters on hole quality. Response surface regression models were subsequently developed to predict and validate optimal drilling parameters. The results indicate that the optimal process parameters for the tapered drill-reamer (TDR) can be achieved by setting the spindle speed within the range of 4878.79/3000 r/min and the feed speed within the range of 34.04/30&#xa0;mm/min, a minimum thrust force of 86.13&#xa0;N and a minimum temperature of 288.35&#xa0;°C are achieved. The trends predicted by the regression model are consistent with the experimental results.</p>

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High-quality drilling analysis of thermoplastic braided carbon fiber composite based on multi-scale simulation and multi-objective optimization method

  • 期刊论文

  • 发表日期：

    2026年1月9日

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  • Yong Liu,
  • Weijie Cheng,
  • Jiadong Huang,
  • Tianyu Wang,
  • Honggen Zhou

摘要

The determination of optimal drilling parameters for Braided Carbon Fiber Reinforced Polyether Ether Ketone (BCF/PEEK) composites is critical for minimizing damage mechanisms such as tearing and delamination, while enhancing tensile strength and extending structural service life. This study proposes a multi-objective optimization method to reduce damage and improve hole quality in BCF/PEEK composites, focusing on the interaction of thermal and mechanical factors. A novel BCF/PEEK composite was fabricated using an advanced molding process, and its mechanical properties were systematically characterized. Three specialized bits were designed and manufactured for BCF/PEEK drilling. A multi-scale thermo-mechanical drilling finite element (FE) model for different drill bits was developed based on a modified micro-mechanics of failure criterion, and the corresponding comprehensive monitoring drilling experimental platform was established to validate the accuracy of the multi-scale FE model. Orthogonal simulation experiments were employed to evaluate the influence of drill bit types and process parameters on hole quality. Response surface regression models were subsequently developed to predict and validate optimal drilling parameters. The results indicate that the optimal process parameters for the tapered drill-reamer (TDR) can be achieved by setting the spindle speed within the range of 4878.79/3000 r/min and the feed speed within the range of 34.04/30 mm/min, a minimum thrust force of 86.13 N and a minimum temperature of 288.35 °C are achieved. The trends predicted by the regression model are consistent with the experimental results.