Defect Suppression Mechanism of CFRP in Longitudinal-Torsional Coupled Ultrasonic Vibration-Assisted Drilling

Carbon fiber reinforced plastic (CFRP) composites have been widely adopted in the aerospace industry due to their excellent mechanical and physical properties. However, their anisotropy and weak interlaminar bonding make them prone to defects such as delamination and fiber pull-out during conventional drilling (CD). Longitudinal-torsional coupled ultrasonic vibration-assisted drilling (LTC-UAD) integrates axial and circumferential vibrations to suppress hole defects and is considered a promising machining method for improving the quality of holes drilled in CFRP. Based on kinematic analysis, a model for the working rake angle of the main cutting edge is established to obtain the variation law of the maximum working rake angle along the cutting edge. Compared with CD and longitudinal ultrasonic vibration-assisted drilling (L-UAD), LTC-UAD significantly increases and homogenizes the maximum working rake angle of the main cutting edge, which helps optimize its cutting performance. A three-dimensional finite element model of CFRP is constructed to analyze the dynamic fiber removal process under typical fiber orientations. Finally, drilling experiments are performed to observe the hole wall micro-morphology at various fiber angles. The simulation results indicate that ultrasonic vibration causes periodic changes in the fiber cutting angle, subjecting the fibers to a directional shear state and making them more prone to shear fracture. Two-dimensional ultrasonic vibration cutting enhances the directional shear effect, promotes fiber fracture, accelerates chip removal, and improves the quality of the machined surface. Experimental observations confirm LTC-UAD alleviates fiber crushing, bare fibers, and surface cavities with uniform resin coverage. Furthermore, ultrasonic vibration suppresses thrust force. L-UAD and LTC-UAD yield 10.6% and 17.1% reductions via periodic cutting depth variation and facilitated carbon fiber shear fracture.