Cutting Force Model in Drilling of Multi-layered Materials

In the aircraft industry, drilling has recently been performed for Carbon Fiber Reinforced Plastics (CFRP)/titanium alloy stacks. The cutting processes should be designed with reviewing in the cutting simulation. The paper presents an analytical model to predict the cutting forces in drilling of multi-layered materials. The force model makes the chip flows on the chisel and the lips with piling up the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities along the cutting edges. The chip flow directions on the chisel and lips are determined to minimize the cutting energies. The cutting force is predicted in the determined the chip flow models. In the CFRP/titanium alloy stacks, the material to be removed changes with the cutter feed. Therefore, the orthogonal cutting data of CFRP and those of titanium alloy are applied to make the cutting models according to the change of material. The force model is verified in comparison between the predicted and the measured cutting forces.