This is a repository copy of Wet vs dry CFRP drilling: Influence of cutting fluid on tool performance. White Rose Research Online URL for this paper: http://eprints.whiterose.ac.uk/136280/ Version: Published Version Article: Kerrigan, K.M. orcid.org/0000-0001-6048-9408 and Scaife, R.J. (2018) Wet vs dry CFRP drilling: Influence of cutting fluid on tool performance. Procedia CIRP, 77. pp. 315-319. ISSN 2212-8271 https://doi.org/10.1016/j.procir.2018.09.024 Reuse This article is distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivs (CC BY-NC-ND) licence. This licence only allows you to download this work and share it with others as long as you credit the authors, but you can’t change the article in any way or use it commercially. 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Scaife physicala architecture of aAdvanced Manufacturing Research Centre with Boeing, Advanced Manufacturing Park, Catcliffe, Rotherham, S60 5TZ, UK existing products for an assembly oriented product family identification Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat * Corresponding author. Tel.: +44-114-222-4839. E-mail address: [email protected] École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France *Abstract Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: [email protected] Carbon fibre reinforced polymer (CFRP) cutting operations have core features which include; i) chip types consisting of sub 50 micron particles and ii) aggressive abrasion-dominated tool wear. The workpieces used in this investigation were manufactured in a single batch from aerospace- Abstract grade, out-of-autoclave, quasi-isotropic, thermoset prepreg materials. Initially, a number of conventional tests were performed to assess the performance of isolated cutting fluid chemicals. The fluid-to-fluid variance was shown to be less significant in these tests when compared against In today’s business environment, the trend towards more product variety and customization is unbroken. Due to this development, the need of dry conditions. A 6 percent basic micro-emulsion concentrate produced the best results with dry setup produced lower torque results than any agile and reconfigurable production systems emerged to cope with various products and product families. To design and optimize production cutting fluid tested. Production-style drilling trials were undertaken to investigate the tool life under varying fluid conditions from basic to systems as well as to choose the optimal product matches, product analysis methods are needed. Indeed, most of the known methods aim to commercially available. These trials indicated that dry, tip-extracted conditions enabled an extended tool life prior to coating failure against the analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and best cutting fluid with identical parameters, machine tool, cutting tool and workpiece material manufacture conditions. The hypothesis for this nature of components. This fact impedes an efficient comparison and choice of appropriate product family combinations for the production reduction in tool performance under general wet conditions is that heat introduced by the drilling process changes the CFRP polymer’s visco- system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster elastic properties thus reducing the abrasive interaction between tool and workpiece during material removal processes. The best cutting fluid, a these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable 5 percent semi-synthetic, commercially available chemistry, produced approximately 60 holes more than the poorest performing chemistry. assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and a ©functional 2018 The analysisAuthors. is Published performed. by Moreover,Elsevier Ltd. a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the similarityThis is an between open access product article families under the by CCproviding BY-NC-ND design license support (https://creativecommons.org/licenses/by-nc-nd/4.0/ to both, production system planners and product) designers. An illustrative exampleSelection of anda nail-clipper peer-review is usedunder to responsibility explain the proposed of the International methodology. Scientiic An industrial Committee case study of the on 8th two CIRP product Conference families ofon steering High Performance columns of thyssenkruppCutting (HPC Presta 2018). France is then carried out to give a first industrial evaluation of the proposed approach. © 2017 The Authors. Published by Elsevier B.V. Keywords: CFRP; cutting fluid; drilling; cost Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. K eywords: Assembly; Design method; Family identification 1. Introduction Nomenclature ANOVA Analysis of variance 1. IntroductionWith amplified focus on global targets to minimise carbon of the product range and characteristics manufactured and/or emission levels, lightweight engineered composite materials, assembledCFRP in this system.Carbon Infibre this reinforced context, the polymer main challenge in suchDue as toCFRP, the are fast experiencing development rapidly in increasingthe domain demand of modellingCVD and analysisChemical is now vapour not deposition only to cope with single communicationwithin sectors andincluding an ongoing aerospace, trend ofautomotive, digitization railand, products,DLC a limitedDiamond- product rangelike coating or existing product families, LSL Lower specification limit digitalization,renewables and manufacturing marine. This enterprises has resulted are in facing a drive important towards but also to be able to analyze and to compare products to define PCD Poly crystalline diamond challengeshigh rate, sustainablein today’s composite market environments:manufacturing process a continuinges that new product families. It can be observed that classical existing UD Unidirectional tendencyachieve towardsdesign intent.reduction The of aerospaceproduct development sector, in particular, times and product families are regrouped in function of clients or features. USL Upper specification limit shortenedrecognises product mechanically lifecycles. fastened In addition, joint theres as isa ankey increasing current However, assembly oriented product families are hardly to find. ILSS Interlaminar shear strength demandprocess offor customization, cost / cycle time being reduction at thes. same time in a global On the product family level, products differ mainly in two In a typical machining operation, Merchant suggested that competition with competitors all over the world. This trend, maininterlocking characteristics: network (i) of the surface number asperities of components [1]. The and effects (ii) theof lubricating cutting fluid influences the process when drawn which is inducing the development from macro to micro typeremoving of components the cutting (e.g. fluid mechanical, from a metal electrical, cutting electprocesronical).s are a n markets,into the tool results-chip in interface diminished by capillary lot sizes action due of to the augmenting Classical methodologies considering mainly single products product varieties (high-volume to low-volume production) [1]. or solitary, already existing product families analyze the To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which identify possible optimization potentials in the existing causes difficulties regarding an efficient definition and production system, it is important to have a precise knowledge comparison of different product families. Addressing this 2212-8271 © 2018 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0/) 2Selection212-8271 ©and 2017 peer-review The Authors. under Published responsibility by Elsevier of the B.V. International Scientiic Committee of the 8th CIRP Conference on High Performance Cutting Peer-review(HPC 2018). under responsibility of the scientific committee of the 28th CIRP Design Conference 2018. 10.1016/j.procir.2018.09.024 316 Kevin Kerrigan et al. / Procedia CIRP 77 (2018) 315–319 increase in friction at the tool-chip interface, an increased shear suitable metric for tracking the wear profile of CFRP-specific