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<p>This research work aims to evaluate the effect of cryogenic cooling on delamination during drilling operations on the carbon fiber reinforced plastic with Al 2024 stack. This research study carefully combines both experimental observations and modeling approaches at two different drilling conditions: one is dry, and the other is cryogenic cooling using N<sub>2</sub>. These two drilling conditions have been evaluated at process parameters such as spindle speed, feed rate (Fr), and drill diameter (Dd). The response surface methodology has been used to analyze the effects of process variables on delamination at both conditions. Results indicated that spindle speed was the most significant effect on delamination followed by Fr and Dd under both drilling conditions. The optimized values of delamination of 1.020 and 1.001 have been attained under dry and N<sub>2</sub> cooling conditions, respectively. The application of cryogenic cooling resulted in a significant reduction of delamination of 3.88% at optimal parametric combination of spindle speed of 600 rpm, feed rate of 800 m/min, and drill diameter of 4 mm. According to optical microscopic analysis, N<sub>2</sub> cooling helped in eliminating the small fuzz and entrance edges which lead to improving the hole quality. Surface roughness of drilled holes reduced from 2.501 to 1.725 am and tool wear from 184 to 159 µm with the variation of cooling condition from dry to cryogenic cooling condition. The friction between workpiece and tool reduces at low cutting temperatures under N<sub>2</sub> cooling condition. As a result, lowering the temperature in the cutting zone mitigates thermal damage to the borehole surface and facilitated the attainment of smoother surfaces and higher tool life. Scanning electron microscopy analysis revealed the better surface integrity, impregnation quality, and fewer fiber pull-outs, which resulted in reduced delamination at cryogenic conditions. The utilization of cryogenic cooling in drilling of CFRP/Al-2024 stacks is deemed advantageous to academic and industrial practitioners to achieve the high-quality drill holes for CFRP/Al-2024 stack material with reducing the tool life and cost associated with drilling operation.</p> Graphical abstract <p></p>

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Evaluating the effect of cryogenic cooling in reducing the delamination during drilling of carbon fiber reinforced plastic (CFRP) and Al 2024 stack

  • 期刊论文

  • 发表日期：

    2025年1月22日

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  • Muhammad Waseem,
  • Muhammad Waqas Hanif,
  • Muhammad Jawad,
  • Salman Hussain

摘要

This research work aims to evaluate the effect of cryogenic cooling on delamination during drilling operations on the carbon fiber reinforced plastic with Al 2024 stack. This research study carefully combines both experimental observations and modeling approaches at two different drilling conditions: one is dry, and the other is cryogenic cooling using N2. These two drilling conditions have been evaluated at process parameters such as spindle speed, feed rate (Fr), and drill diameter (Dd). The response surface methodology has been used to analyze the effects of process variables on delamination at both conditions. Results indicated that spindle speed was the most significant effect on delamination followed by Fr and Dd under both drilling conditions. The optimized values of delamination of 1.020 and 1.001 have been attained under dry and N2 cooling conditions, respectively. The application of cryogenic cooling resulted in a significant reduction of delamination of 3.88% at optimal parametric combination of spindle speed of 600 rpm, feed rate of 800 m/min, and drill diameter of 4 mm. According to optical microscopic analysis, N2 cooling helped in eliminating the small fuzz and entrance edges which lead to improving the hole quality. Surface roughness of drilled holes reduced from 2.501 to 1.725 am and tool wear from 184 to 159 µm with the variation of cooling condition from dry to cryogenic cooling condition. The friction between workpiece and tool reduces at low cutting temperatures under N2 cooling condition. As a result, lowering the temperature in the cutting zone mitigates thermal damage to the borehole surface and facilitated the attainment of smoother surfaces and higher tool life. Scanning electron microscopy analysis revealed the better surface integrity, impregnation quality, and fewer fiber pull-outs, which resulted in reduced delamination at cryogenic conditions. The utilization of cryogenic cooling in drilling of CFRP/Al-2024 stacks is deemed advantageous to academic and industrial practitioners to achieve the high-quality drill holes for CFRP/Al-2024 stack material with reducing the tool life and cost associated with drilling operation.

Graphical abstract