The new developed metal/composite co-cured material composed of carbon fiber–reinforced plastic and Al phases has been increasingly applied for manufacturing of attitude control flywheel in aerospace industry. However, drilling of co-cured material is still a challenging task to produce holes with high quality and low cost in the assembly chain and dynamic balance debugging of attitude control flywheel. In other words, the relevant mechanisms and experimental findings involved in the drilling process of carbon fiber–reinforced plastic/Al co-cured material is not clearly defined, which impedes the progress of attitude control flywheel production. To this end, this article specially addresses the experimental studies on the drilling process of carbon fiber–reinforced plastic/Al co-cured material with standard TiAlN-coated cemented carbide twist drill. The significance of this work aims to reveal the regardful cutting responses of the hole characteristics and tool wear modes during the practical drilling process of co-cured material. A full factorial experiment including three levels of feed rate and four levels of cutting speed was performed. The hole diameter shows different values in different positions while it indicates consistent pattern regardless of the cutting variables: the largest in the Al phase, followed by the upper and lower carbon fiber–reinforced plastic phases, respectively. Grooves and matrix degradation are the major machining defects for carbon fiber–reinforced plastic layers, while a great chip debris adhered to the machined surface is the case for Al layer. Subsequent wear analysis showed that abrasion was mainly maintained at the vicinity of major/minor cutting edges and drill edge corner, followed by chip adhesion on the chisel edge region. Carbide substrate of drill flank face is exposed, and thereafter cavities are formed under the strong mechanical abrasion. These results could provide several implications for industrial manufacturers during the attitude control flywheel production.

中文翻译：

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干钻新开发的金属/复合共固化材料时的孔质量和刀具磨损

新开发的由碳纤维增强塑料和铝相组成的金属/复合共固化材料越来越多地应用于航空航天领域的姿态控制飞轮制造。然而，共固化材料的钻孔仍然是组装链中高质量低成本钻孔和姿态控制飞轮动平衡调试的一项具有挑战性的任务。换句话说，碳纤维增强塑料/铝共固化材料钻孔过程中涉及的相关机制和实验结果没有明确定义，这阻碍了姿态控制飞轮生产的进展。为此，本文专门针对标准TiAlN涂层硬质合金麻花钻对碳纤维增强塑料/Al共固化材料的钻孔工艺进行了实验研究。这项工作的意义旨在揭示在共固化材料的实际钻孔过程中孔特征和刀具磨损模式的相关切削响应。进行了包括三个级别的进给率和四个级别的切削速度的全析因实验。孔径在不同位置显示不同的值，而无论切削变量如何，它都显示出一致的模式：Al 相中最大，其次是上部和下部碳纤维增强塑料相，分别。凹槽和基体退化是碳纤维增强塑料层的主要加工缺陷，而大量的切屑附着在加工表面上是铝层的情况。随后的磨损分析表明，磨损主要维持在主/副切削刃和钻头刃角附近，其次是横刃区域的切屑粘附。钻头后刀面的硬质合金基体暴露出来，然后在强烈的机械磨损下形成空腔。这些结果可以在姿态控制飞轮生产过程中为工业制造商提供一些启示。然后在强烈的机械磨损下形成空腔。这些结果可以在姿态控制飞轮生产过程中为工业制造商提供一些启示。然后在强烈的机械磨损下形成空腔。这些结果可以在姿态控制飞轮生产过程中为工业制造商提供一些启示。