Rotary ultrasonic machining of CFRP composites

Drilling is a major machining process performed for assembly purposes in CFRP composite applications. Traditional methods of drilling CFRP composites (including twist drilling and its relative methods) have many machining problems such as short tool life, poor hole quality and low machining efficiency. There are critical needs to develop time-efficient and cost-effective processes for drilling CFRP composites. Rotary ultrasonic machining (RUM) can be one of them. This chapter presents RUM of CFRP composites, including definitions, features, machine elements (system set-up) as well as experimental and theoretical investigations. These investigations include effects of input variables (tool rotation speed, feed rate and ultrasonic power) on cutting force, torque, cutting temperature, edge quality, surface roughness, burning of machined surface, tool wear, material removal rate (MRR), power consumption and feasible regions during RUM of CFRP composites.