Composite Drilling Thrust Force Mapping by Fiber Cutting Angle
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Solution Overview
Problem
Existing methods fail to accurately measure the distribution of thrust force during drilling of unidirectional composites due to inability to detect the rotation angle of the tool and position of the cutting edge, leading to fluctuations in thrust forces that cause layering and damage.
Innovation Solution
A method involving cutting a groove in a sample piece to define the tool's rotation position, measuring the thrust force during drilling, and analyzing the time-dependent curve to determine the fiber cutting angle and corresponding thrust force distribution without altering the drilling state or experimental platform.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing thrust force measuring instruments are used during drilling, then thrust force can be measured, but the rotation angle of the tool and position of the cutting edge cannot be identified
Solution Approach 1:
A groove is introduced as an intermediary reference feature on the workpiece surface. This groove serves as a fixed reference that interacts with the rotating cutting tool, enabling the determination of cutting edge position and rotation angle through the timing relationship between groove detection and thrust force measurement
Solution Approach 2:
The system establishes feedback by detecting thrust force variations as the cutting edge passes over the groove reference feature. This feedback loop allows correlation between thrust force measurements and tool rotation position, enabling accurate determination of fiber cutting angles
2Measurement precision
If thrust force measurement is performed during drilling of unidirectional composites, then drilling quality can be monitored, but the periodic fluctuation of thrust force makes it difficult to determine fiber cutting angle
Solution Approach 1:
The method utilizes the natural periodic fluctuation of thrust force during drilling as a self-contained signal source. By analyzing the inherent thrust force variations and correlating them with the groove reference feature, the system determines fiber cutting angles without requiring additional sensors or complex measurement devices
Solution Approach 2:
A groove reference feature is pre-formed on the workpiece surface before drilling operations. This preliminary action creates a fixed reference that remains throughout the drilling process, enabling consistent correlation between thrust force measurements and tool position without requiring real-time adjustments
3Measurement precision
If the drilling state or experimental platform is changed to measure thrust force distribution, then accurate measurement may be achieved, but the operation becomes complex and drilling conditions may be altered
Solution Approach 1:
The method changes the reference frame parameter by introducing a fixed groove feature on the workpiece instead of changing the drilling parameters or platform configuration. This allows thrust force distribution to be measured in relation to fiber cutting angles while maintaining standard drilling conditions and platform setup
Data Source
AI summary
The present invention belongs to the technical field of machining of fiber-reinforced composites, and relates to a method for measuring distribution of a thrust force during drilling of a unidirectional composite along with a fiber cutting angle. The method includes: cutting the surface a composite sample piece to form a groove; drilling on an existing experimental platform for measuring a thrust force during drilling, where a through hole obtained through the drilling is required to intersect with the groove; obtaining a curve of the thrust force during drilling, comparing the curve with a conventional curve of the thrust force to find a mutation point, and determining the mutation point, namely a fiber cutting angle at the groove; and calculating fluctuation periods of the thrust force according to machining parameters to reckon the distribution of the thrust force along with the fiber cutting angle in all the periods.