Abstract:
Single-shot drilling of carbon fiber-reinforced polymer/titanium
alloy stacks in aerospace applications poses unique challenges.
The interaction between the cutting tool and the composite-
metal contact often leads to poor hole quality and increased
tool wear. The review extensively examines research achieve
ments and developments in drilling CFRP/Ti stacks to compre
hensively assess the impact of various machining settings on
hole quality. Contributing factors such as stack-up machining
thrust force, temperature, chip form and tool wear characteris
tics are thoroughly investigated. Moreover, this article high
lights manufacturing defects in metallic and composite panels
during drilling operations, contributing to a higher rejection
rate in the assembly process. Usually, the maximum delamin
ation of 1mm, diameter deviation of ±30mm, burr height of
150mm, metal part’s surface roughness of 1.6mm and CFRP
part’s surface roughness of 3.2mm are allowed in the aero
space industry. Additionally, the research explores strategies
to mitigate manufacturing defects, including measures to limit
hole and tool damage. These tactics encompass tool structure,
machining environment, machining parameters and machin
ing technology. On the whole, this review study aims to fill
the research gap regarding process enhancement and per
formance evaluation of single-shot drilling of CFRP/Ti stacks in
aerospace applications.
