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Procedia CIRP 108 (2022) 94–99
www.elsevier.com/locate/procedia

6th CIRP Conference on Surface Integrity

Ultrasonic Vibration and Cryogenic assisted drilling of Aluminum-CFRP

Composite Stack – An innovative approach
R. Bertolinia*, N.Tamil Alaganb,c, A. Gustafssonb, E. Savioa, A. Ghiottia, S. Bruschia

a
Department of Industrial Engineering, University of Padova, Via Venezia 1, 35131, Padova, Italy
b
Department of Engineering Science, University West, Gustava Melins gata 2, Trollhättan, Sweden
c
Innovation and Technology, Hydro Extrusion Hungary KFT, 8000 Székesfehérvár, Hungary
* Corresponding author. Tel.: +39-049-827-6819; fax: +39-049-827-6819. E-mail address: [email protected]

Abstract

The request for more resistant but still light components has focused the manufacturing industry's interest in composite materials. The
manufacturing of parts made of composite may require drilling operations; nevertheless, assuring a good hole quality still represents a challenge
for these materials. The present work provides, for the first time, a comparison between different drilling technologies, namely ultrasonic drilling
and cryogenic drilling, proposing them as alternatives to dry drilling. After drilling, the hole surface quality is characterized in terms of
geometrical accuracy and delamination. Results show that innovative cutting methods can significantly improve the drilling performances within
a well-defined process parameters window.
© 2022 The Authors. Published by Elsevier B.V.
This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer review under the responsibility of the scientific committee of the 6th CIRP CSI 2022

Keywords: Fiber Metal Laminates; Ultrasonic Vibration; Cryogenic; Drilling; Hole quality; Delamination

1. Introduction these drawbacks, other drilling approaches, namely Ultrasonic

Drilling (UD) and Cryogenic Drilling (CD), have been recently
Carbon Fiber Reinforced Plastics (CFRP) are increasingly proposed, as alternatives to Regular Drilling (RD).
used in parts for aerospace applications thanks to their high With regard to UD, in [3] a Langevin-type piezoelectric
strength-to-weight ratio [1]. They are used alone for floor ultrasonic transducer was designed to impart a high-frequency
panels or interiors as well as in combination with dissimilar axial vibration to the drill bit. Compared to conventional
materials, like aluminum or titanium alloys to form a Fiber drilling, the Authors found a reduction of the delamination area
Metal Laminate (FML), thus in form of stacks of composites to of approximately 50%, as well as increased hole roundness and
be used for wing or airplane parts. surface finish during drilling a CFRP.
Such parts usually contain multiple holes, like the ones In [4] the effect of the cooling strategy, namely dry and
needed for bolts or rivets. Nevertheless, obtaining a precise hole cryogenic conditions, on the hole quality of magnesium alloy-
with tight tolerances in FML structures is extremely based FMLs was investigated at varying drill bits. Results
challenging due to the mismatch in the coefficient of linear showed that, in the case of conventional twist drills, the
expansion and elastic modulus of the joined materials. In cryogenic approach helped in containing the cylindricity and
addition, the use of cutting fluids, which is customary in cutting, size errors compared to the ones obtained under dry conditions.
is to be avoided since the oil can be absorbed by the polymer In [5], the cryogenic approach was used to drill CFRP parts in
matrix, altering its mechanical properties [2]. To overcome comparison to dry and Minimum Quantity Lubrication (MQL)

2212-8271 © 2022 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0)
Peer review under the responsibility of the scientific committee of the 6th CIRP CSI 2022
10.1016/j.procir.2022.03.020

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 R. Bertolini et al. / Procedia CIRP 108 (2022) 94–99 95

conditions. A better hole quality in terms of nominal diameter movements of the UD system are shown in Fig. 1c).
and roundness was achieved in the cryogenic case thanks to the The cryogenic cooling apparatus consists of a dewar, in
preservation of the drill bit sharpness. On the basis of the which the liquid nitrogen (LN2) is stored at 24 bars, a vacuum
literature review and in virtue of the growing interest in insulated pipe to transfer the LN2 in liquid form from the tank
composite parts, the present work deals with the comparison of to the cutting tool position, and a nozzle pointed to the cutting
different innovative drilling approaches in order to highlight the edges of the drill bit to spray the LN2. A GMA 1010 F31B
one leading to the highest hole quality. To this aim, an commercially available nozzle with a diameter of 1.016 mm
experimental campaign including RD, UD and CD was was used, characterized by ruby insert and stainless steel body.
performed at varying feed. The hole characteristics were The nozzle was placed approximately 60 mm far away from the
assessed in terms of size, cylindricity, perpendicularity, and workpiece, in order not to interfere with the drilling operation,
delamination. but close enough to efficiently cool the drill bit.
Figure 1a) illustrates the experimental apparatus, whereas
2. Experimental procedure
Fig. 1b) gives a closer view of the tank and holder in case of
cryogenic cooling. Figure 1c) shows a view of the drill bit
2.1. Workpiece and cutting tool
mounted on the ultrasonic tool holder during a test under
cryogenic cooling. The hybrid composite stack workpiece was
The composite material object of this study is a hybrid
firmly fixed to the machine tool table by means of two screws
composite stack composed of a 5 mm thick Aluminum alloy
using a custom pocket-designed wooden plate. The function of
(Al) sheet and a 4 mm thick CFRP sheet, joined together with
the wooden plate was twofold: i) to act as a thermal insulator
a commercial glue. The workpiece was supplied in a form of a
to preserve the integrity of the load cell, and ii) to allow
rectangle of 230 mm length and 245 mm height. Such type of
fabricating a through-hole without interfering with the process,
composite is extensively used in aerospace applications since it
being characterized of a hollow surface. To investigate the
can assure the strength and durability of the component.
effect of the cutting conditions on the exit delamination, the
The cutting tool selected for the drilling campaign was a
workpiece was fixed in the way that the Al sheet lies on the top
commercially available solid carbide drill, whose main
while the CFRP one is on the bottom.
geometrical specifications are given in Table 1. The selected
tool was characterized by a highly polished surface to facilitate
the chip evacuation and reduce the built-up edge formation, and
a sharp cutting edge as suggested by the tool manufacturer to
improve the tool life when machining non-ferrous alloys.

Table 1. Cutting tool nomenclature and geometry specifications.

ISO code B284D08000HPS

Type of insert Uncoated solid carbide
Grade KN15
Drill diameter (mm) 5
Drill shank diameter (mm) 6
Drill overall length (mm) 66
Flute length (mm) 28
Maximum drilling depth (mm) 20
Drill point length (mm) 0.923

Shank length (mm) 36

Point angle (°) 135

2.2. Experimental setup

The drilling campaigns were carried out on a DMG™ Mori

635 V ecoline 3-axis milling machine, equipped with UD and
CD systems. The Ultrasonic Vibration (UV) system includes
an ultrasonic tool holder with a collet size of 6 mm diameter,
connected to an external generator. The tool vibrates at a
frequency of approximately 21 Hz with an amplitude in the
range of 5÷ 5.4 µm, calculated considering both the tool stick Fig. 1. a) Overall view of the UD and CD systems, b) closer view of the tank
out length and weight [6]. The axial vibration and rotation and holder of the CD system, and c) drilling process setup.

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A Kistler™ force sensor was mounted on the center of the 3. Results and discussion
table, below the wooden plate to preserve it to get in contact
with the LN2. In addition, polystyrene thermoforms surrounded 3.1. Thrust forces
the dynamometric table to further protect it from unwanted
Figure 2 shows the recorded thrust forces that were
temperature variations. The force sensor data was transferred
generated at varying drilling strategy and intermediate feed. On
through the dynamometer cable to the data collector DAQ, then
average, the thrust force when drilling the Al sheet was three to
processed with the Dynoware™ data processing software.
four times higher than the one recorded when drilling the CFRP
2.3. Drilling experiments sheet. Obviously, this is due to the higher metal strength
compared to that of the CFRP. Figure 3 reports the thrust force
To assess the impact of the proposed innovative drilling
as the average of the values recorded during the three
technologies on the hybrid composite stack hole quality, UD
repeatability and subdivided for the aluminum and CFRP
and CD experiments were carried out. For sake of
sheets. The difference in the average thrust forces generated
comprehension, RD was also performed. Three levels of feed
during RD and UD was limited, attesting to the same average
(f= 0.05 mm/rev, f= 0.1 mm/rev, and f= 0.15 mm/rev) were
value for both the materials, whereas it is drastically increased
chosen for the drilling trials, keeping fixed the cutting speed to
when applying LN2. Compared to RD, in the case of Al, CD
vc=60 m/min. The cutting speed value was chosen considering
led to the increase of the thrust force of 20%, 27% and 23% for
both the available literature studies and the technical
the feed of 0.05, 0.1 and 0.15 mm/rev, respectively, when
limitations of the machine. From the former, it can be deduced
drilling the Al sheet. Similarly, when drilling the CFRP sheet,
that the cutting speed does not have a clear trend in influencing
CD registered an increase of 62%, 53% and 45% compared to
the hole quality [4]. On the contrary, different feed were
the RD strategy. This can be ascribed to the temperature
investigated since the feed is well-known to be the most
reduction provided by the application of LN 2 that increases the
significant variable in conditioning the hole quality, especially
material shear strength with a consequent rise of the cutting
in terms of delamination.
force. Contrarily, during both RD and UD, the thrust force is
The overall experimental campaign is summarized in Table
lower due to the polymer matrix and metal softening promoted
2. For each condition, a new tool was used and in total 3
by the temperature increase [5]. It is worth noting that the thrust
holes/tool were machined for each cutting condition.
force for UD is slightly lower for CD, except for the highest
After drilling, the workpiece was inspected utilizing optical
feed which registered a 5% and 11% increment when drilling
microscopy to identify any exit delamination.
the metal and the composite sheets, respectively.
Table 2. Experimental plan.

Cutting speed (m/min) 60

Feed rate (mm/rev) 0.05, 0.1, 0.15
Hole type Through
Regular Drilling (RD)
Drilling strategy Ultrasonic Drilling (UD)
Cryogenic Drilling (CD)

2.4. Measurement of the drilled holes geometry

The evaluation of the hole geometrical accuracy was carried

out through contact scanning on a Zeiss™ Prismo Vast 7
Coordinate Measuring Machine (CMM), characterized by a
maximum permissible error of (2.2+L/300) μm, with L = length
in mm. The used probe had a spherical tip of 2 mm diameter.
Each hole datum system was determined by measuring the
upper surface using 8 points in a circular pattern around the
hole. Four circular sections per hole were acquired at different
levels, acquiring 425 points for each circle at 0.5 mm/s
scanning speed. Two sections were on the Al sheet (1.5 and 3.5
mm from the upper surface) and two on the CFRP sheet (6.5
and 7.5 mm from the upper surface). The hole diameter was
evaluated by computing a cylinder using the four scanned
circles and a Gaussian association criterion. The evaluation of
the cylindricity (according to the ISO 1101:2017 standard) was
based on minimum zone fitting of the reference cylinders and
a Gaussian long-wave pass filter with 15 undulations per
revolution.
Fig. 2. Thrust force evolution at varying drilling strategy for f=0.1 mm/rev.

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This indicates that UD loses efficiency at the highest feed, Figure 4 shows the hole diameters for each hybrid composite
as indicated by the analytical formulae given in [7]. Actually, stack material, determined as the average of two different
in UD, the tool cutting edge trajectory is represented by a measurements on each of the three holes drilled for each feed
sinusoidal curve, and the linear distance between two and drilling strategy. Irrespective of the cutting condition and
subsequent cutting paths of the cutting edge varies periodically. hybrid composite stack material, all the holes were oversized
The interception leads to chips break, and it likely occurs in the with respect to the nominal diameter value (5 mm). This fact is
case of lower feeds, as seen in the present study. unusual for CFRP, since holes are usually undersized in FLM
The thrust forces drastically increase at increasing feed for parts due to the presence of uncut fibers as well as to the
the aluminum sheets, regardless of the drilling strategy, in relaxation of stresses originated by the mismatch between the
accordance with many previous studies [5]. The higher the feed elastic modulus and coefficient of thermal expansion of the
the higher the chip cross-sectional area, hence the resistance to FML different materials [10]. It is worth noting that the highest
cutting. A different scenario is seen for the CFRP sheets. diameter variation with the respect to the nominal value was
Actually, compared to the lowest feed, the thrust force registered for the aluminum sheet, and that no sensible
increases solely of 5% and 7% for f=0.1 mm/rev and f=0.15 differences can be appreciated at varying drilling approach.
mm/rev in case of RD, of 7% and 18% for f=0.1 mm/rev and For the CFRP, at both the lowest and intermediate feed, the
f=0.15 mm/rev in case of UD, and decreases of -1% and -5% minimum variation in the hole size was observed in the case of
for f=0.1 mm/rev and f=0.15 mm/rev in case of CD. The reason UD, whereas the maximum one was observed in the case of
for the trivial increase of the thrust force at increasing feed can RD, with CD and RD settled to comparable values. At the
be ascribed to the mitigation effect given by the heat generation highest feed, no sensible differences were found among the
in the correspondence of the drilling zone that causes the drilling strategies. Additionally, it can be seen that, in the case
decrease of the polymer matrix strength. of UD, the hole diameter slightly increased at increasing feed.
UD is, in fact, an intermittent cutting process that leads to the
formation of discontinuous chips in contrast to the
conventional process, and its efficiency is maximized at low
feeds as previously stated [7]. The better chip evacuation
contributes to reduce sliding friction against the drill tool,
therefore promoting more stable cutting conditions. A different
scenario was seen in the case of both RD and CD, since a clear
trend with the feed was not possible to be highlighted.

Fig. 3. Average thrust force at varying feed and drilling strategy.

Fig. 4. Average hole diameter at varying feed and drilling strategy.
3.2. Drilled holes dimensional accuracy
3.3. Drilled holes cylindricity
Dissimilar mechanical and thermal properties of the
materials of the FML can result in either undersized or Cylindricity is used to describe the closeness of a
oversized hole diameter, making the manufacturing of a manufactured cylindrical surface to a true cylinder. It is a
consistent hole throughout the stack challenging. Using an commonly used parameter to quantify the global geometrical
undersized hole with a screw or a rivet may concentrate stresses accuracy of manufactured holes [11].
at the hole walls, resulting in crack initiation and propagation Figure 5 shows the cylindricity as a function of the feed and
till the component failure, whereas, using an oversized hole for drilling strategy. It is worth noting that the cryogenic coolant
joining materials may result in a loose assembly and possible use improved the cylindricity at the highest feed, whereas the
bearing failure [8]. In general, it can be stated that precise holes application of UD was more effective at the lowest feed. No
were manufactured since their size was within the suggested sensible differences between the drilling strategy were found at
tolerance, namely ±40 µm, proposed by Sandvik Coromant™ the intermediate feed. Furthermore, it is worth noting that no
for reliable drilling in aerospace applications [9]. correlation between the cylindricity and thrust forces was

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found since the former did not increase either rising the feed or
in the case of CD. Nevertheless, it can be stated that the
cylindricity is affected by the cutting temperature since it is
lowest in the case of CD at the highest feed, the latter implying
the highest temperature rise.

Fig. 6. Perpendicularity at varying feed and drilling strategy.

3.5. Delamination

Minimization of delamination damage is of great

importance as delamination represents a critical parameter that
Fig. 5. Cylindricity at varying feed and drilling strategy. determines the acceptance or rejection of composite
components [14]. This type of damage can occur on both the
3.4. Drilled holes perpendicularity top and bottom surfaces of the hybrid composite stack;
nevertheless, in the present work, due to the nature of the
Perpendicularity is one of the most common geometrical workpiece, it has been evaluated solely at the exit since the
specifications (ISO 1001:2017), and is used for the assessment entrance appears defects free (see Fig. 7). In literature, the
of the orientation of the axis of both positive and negative extent of drilling-induced delamination has been widely
features, like pins and holes [12]. Perpendicularity is an associated with the thrust force values and it is believed that
essential parameter to be minimized in bolted structural joints, there is a critical thrust force below which delamination is
otherwise, the contact area between the outer edge of the nuts prevented [15].
and the bolt heads is reduced causing a significant stress Fig. 8 shows the hybrid composite stack exit delamination
concentration. This is why a perpendicularity below 0.01 mm at varying feed and drilling strategy. It can be seen that severe
is highly desired in the case of aerospace structures [13]. In exit delamination occurred solely when drilling tests were
general, regardless of the process parameters, all the drilled conducted under CD, regardless of the adopted feed. Similar
holes stayed within the suggested perpendicularity results were obtained in [5]. This phenomenon can be
specification witnessing that a good hole was manufactured. correlated to the thrust force increase thanks to the hardening
The maximum hole perpendicularity value was obtained in of material as a consequence of the application of liquid
the case of RD at the lowest feed, while the minimum in the nitrogen, as clearly depicted in Fig. 3 [16].
case of CD at the highest feed. The same trend found for the It is acknowledged that the higher the thrust force the greater
hole diameter can be highlighted for UD: the perpendicularity the exit delamination because the deflection of the FML last
increases at increasing feed. On the contrary, for both RD and ply interests a larger zone [15].
CD, lower perpendicularity errors are obtained at the highest
feed. Again, also in this case, a correlation between the
perpendicularity and the thrust force cannot be highlighted as
in [12]. The dimensional stability of a material depends on its
thermal expansion coefficient, namely the thermal expansion
coefficients of its constituents in the case of an FML, whose
effect becomes critical at those temperatures generated during
machining processes. The variations in the size of the holes in
the aluminium sheet are greater than those in the CFRP sheet,
as shown in Fig. 4. The rise in the workpiece temperature
increases the thermal distortions in the hybrid composite stack,
hence influencing the hole perpendicularity. Contrarily,
cryogenic cooling helps in containing the perpendicularity
since it reduces the temperature increase.
For what concerns the UD strategy, it can be assumed that
the chip formation efficiency, which is reduced at higher feeds,
played the major role over the temperature increase.
Fig. 7. Entry delamination on the aluminium sheet at varying feed and drilling
strategy.

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 R. Bertolini et al. / Procedia CIRP 108 (2022) 94–99 99

both UD and RD present also lower thrust forces

compared to CD, limiting exit delamination.
5. Acknowledgement
We would acknowledge the following projects for financial
support: NexT- LighT (Ref.No: 2020-04292) with support
from the strategic innovation program LIGHTer, DNR-2019-
02637 Ultrasonic Vibration Assisted Machining Advanced
aluminum alloys, a joint venture by Vinnova, Formas, and the
Swedish Energy Agency. CryoMach (Ref.No: 2018-03332)
with support from Vinnova (Swedish Government Agency for
Innovation Systems) and Eureka SMART Advanced
Manufacturing. Special thanks to Mr Jack Lee from Acrow
Taiwan, Ms Lena Bernhed, from PNR Nordic. Mr Kalle Falk
from Fortiva Tools, Dr Stefan Cedergren GKN Aerospace,
Sweden and Mr Anders Mejlvang Micro-Epsilon, Sweden.
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