Review of One-shot Drilling on Carbon Fiber-reinforced Thermosetting Composite and Metal Stacks

doi:10.3901/JME.2025.07.001

Abstract

Abstract: Carbon fiber-reinforced thermosetting composite (“thermoset composite”)/metal stack represents a prevalent structural format in high-end equipment, with one-shot drilling emerging as a pivotal aspect for achieving seamless connection and assembly of these stacks. However, the stark differences in their physicochemical properties often lead to frequent drilling-induced damages, posing a challenge to meeting the pressing demands of the engineering sector. Consequently, the pursuit of high-quality and efficient one-shot drilling technology for thermoset composite/metal stacks has garnered significant attention in recent years, prompting extensive and valuable research endeavors from both academic and engineering circles. This study comprehensively reviews the latest advancements in one-shot drilling technology for stacks, encapsulating four key aspects: the co-cutting removal behavior of the interface region, drilling force, heat generation, and chip behavior, low-damage drilling bits, and low-damage drilling processes. Firstly, the research progression of the co-cutting removal behavior at both macro and micro cutting levels are discussed, detailing the interface region's characteristics. Secondly, the evolution and variation patterns of thrust force, drilling temperature, and chip formation during the one-shot drilling process of stacks are analyzed. Subsequently, the historical development of low-damage one-shot drilling tools for stacks is summarized and the influence mechanisms of drilling process parameters, as well as the effects of cooling and vibration assistance, on hole quality, are elucidated. Lastly, the future trajectory and challenges facing cutting theories, drilling technologies, and process equipment for CFRP/metal stacks are discussed.

Key words: thermoset composite/metal stacks, cutting mechanism, drilling bits, drilling process, damage reduction

CLC Number:

TG71

ZHAO Meng, FU Rao, WANG Fuji, ZHAO Hongwei, LI En, DU Changlin. Review of One-shot Drilling on Carbon Fiber-reinforced Thermosetting Composite and Metal Stacks[J]. Journal of Mechanical Engineering, 2025, 61(7): 1-23.

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