作者：朱萍玉, 李永敬, 孙孝鹏, 李东炜

作者单位：广州大学机械与电气工程学院, 广东 广州 510006

关键词：纤维增强复合材料;制孔分层;缺陷检测;评价因子

摘要：

纤维增强复合材料的制孔工序是实现复合材料结构件连接的重要环节，复合材料的各向异性和层间强度低极易导致分层缺陷，而制孔质量直接影响复合材料零部件物理性能的发挥和安全服役中的可靠性。因此，必须对复合材料制孔的分层缺陷进行检测并加以评价，用以优化刀具设计和加工工艺参数。该文在简要阐述制孔分层缺陷产生机理的基础上，首先，重点分析渗透液、光学、渗透X射线、常规超声C扫描、工业CT和超声显微镜6种分层缺陷检测方法的基本原理、特点及研究进展；然后，分类总结制孔分层缺陷的7种定量评价因子；最后，讨论复合材料制孔缺陷在线监测与评价的可行性和所面临的技术挑战。

Research progress on detection and evaluation technology of drilling delamination defect for fiber reinforced plastic

ZHU Pingyu, LI Yongjing, SUN Xiaopeng, LI Dongwei

School of Mechanical and Electric Engineering, Guangzhou University, Guangzhou 510006, China

Abstract: Hole making process of fiber reinforced composite is a vital part to realize the connection of composite structure parts. But the anisotropy of the composite material and low strength between the layers would easily result in delamination defects, which directly affects the physical properties of composite parts and reliability in the security service. Therefore, it is necessary to detect and evaluate the delamination defects in composite holes, which helps to optimize the design of the tool and process parameters. After a brief exposition of generation mechanism of delamination defects, this paper mainly analyses the basic principle, characteristics and research progress of six different delamination detection methods, such as penetrant, optical, X-ray, ultrasonic C-scan, CT and ultrasonic microscope detection. Then, seven kinds of quantitative evaluation factors for delamination are classified and summarized. And finally, the feasibility of on-line monitoring and evaluation of delamination during drilling composite materials and technological challenges are discussed.

Keywords: FRP;drilling delamination;defect detection;evaluation factor

2018, 44(1): 1-8  收稿日期: 2017-07-14;收到修改稿日期: 2017-08-20

基金项目: 广东省科技计划项目（2016A010102020）；广州市科技计划项目（201607010292）

作者简介: 朱萍玉(1971-),女,湖北钟祥市人,教授,博士,研究方向为光纤传感器技术、结构健康监测与智能维护。

参考文献

[1] SOUTIS C. Fibre reinforced composites in aircraft cons-truction[J]. Progress in Aerospace Sciences,2005,41(2):143-151.
[2] 张厚江. 碳纤维复合材料(CFRP)钻削加工技术的研究[D].北京:北京航空航天大学,1998.
[3] 明伟伟,王昌赢,魏莹莹,等. 纤维增强复合材料制孔刀具技术研究进展[J]. 航空制造技术,2013(14):34-37.
[4] WANG Y Q, BAO Y J, GAO H. Studies on disfigure-ment-fee technology of drilling carbon fiber reinforced plastics[J]. Advanced Materials Research,2007(24/25):125-132.
[5] DAVIM J P, RUBIO J C, ABRAO A M. A novel approach based on digital image analysis to evaluate the delamination factor after drilling composite laminates[J]. Composites Science and Technology,2007,67(9):1939-1945.
[6] TSAO C C, HOCHENG H. Computerized tomography and c-scan for measuring delamination in the drilling of composite materials using various drills[J]. International Journal of Machine Tools and Manufacture,2005,45(11):1282-1287.
[7] HOCHENG H, DHARAN C K H. Delamination during drilling in composite laminates[J]. Journal of Engineering for Industry,1990,112(3):236-239.
[8] DAVIM J P, REIS P. Drilling carbon fiber reinforced plastics manufactured by autoclave-experimental and stati-stical study[J]. Materials & Design,2003,24(5):315-324.
[9] CHEN W C. Some experimental investigations in the drilling of carbon fiber-reinforced plastic(CFRP) composite laminates[J]. International Journal of Machine Tools & Manufacture,1997,37(8):1097-1108.
[10] PALANIKUMAR K, RUBIO J C, ABRAO A, et al. Statistical analysis of delamination in drilling glass fiber-reinforced plastics(GFRP)[J]. Journal of Reinforced Plastics & Composites,2008,27(15):1615-1623.
[11] TSAO C C, HOCHENG H. Effects of exit back-up on delamination in drilling composite materials using a saw drill and a core drill[J]. International Journal of Machine Tools & Manufacture,2005,45(11):1261-1270.
[12] SILVA D, TEIXEIRA J P, MACHADO C M. Methodology analysis for evaluation of drilling-induced damage in composites[J]. International Journal of Advanced Man-ufacturing Technology,2014,71(9):1919-1928.
[13] LIU D F, TANG Y J, CONG W L. A review of mech-anical drilling for composite laminates[J]. Composite Structures,2012,94(4):1265-1279.
[14] HOCHENG H, TSAO C C. The path towards delamination-free drilling of composite materials[J]. Journal of Materials Processing Technology,2005,167(2/3):251-264.
[15] DURAO L M P, TAVARES J M R S, ALBUQUERQUEl V H C D, et al. Damage evaluation of drilled carbon/epoxy laminates based on area assessment methods[J]. Composite Structures,2013,96(4):576-583.
[16] 魏莹莹,安庆龙,蔡晓江,等. 碳纤维复合材料超声扫描分层检测及评价方法[J]. 航空学报,2016,37(11):3512-3519.
[17] LAZAR M B, XIROUCHAKIS P. Experimental analysis of drilling fiber reinforced composites[J]. International Journal of Machine Tools & Manufacture,2011,51(12):937-946.
[18] 张厚江,陈五一,陈鼎昌. 碳纤维复合材料钻削孔分层缺陷的研究[J]. 中国机械工程,2003,14(22):1978-1980.
[19] DAVIM J P, REIS P, ANRONIO C C. Experimental study of drilling glass fiber reinforced plastics(GFRP) manufactured by hand lay-up[J]. Composites Science & Technology,2004,64(2):289-297.
[20] TAGLIAFERRI V, CAPRINO G, DITERLIZZI A. Effect of drilling parameters on the finish and mechanical properties of GFRP composites[J]. International Journal of Machine Tools & Manufacture,1990,30(1):77-84.
[21] MURPHY C, BYRNE G, GILCHRIST M D. The performance of coated tungsten carbide drills when machining carbon fibre-reinforced epoxy composite materials[J]. Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture,2002,216(2):143-152.
[22] JOHNSON W S, TREASURER P. Radiographic investigation of the effects of ply modification on damage development in laminates containing circular holes[J]. Journal of Composite Materials,2008,42(20):2143-2161.
[23] SILVA D N R D. Image processing methodology for assessment of drilling induced damage in CFRP[J]. Faculdade De Ciências E Tecnologia,2013.
[24] 宋瑶,王园. 水浸式脉冲反射板法检测复合材料碳纤维层压板分层缺陷[C]//中国航空学会青年科技论坛,2014.
[25] TSAO C C, KUO K L, HSU I C. Evaluation of a novel approach to a delamination factor after drilling composite laminates using a core-saw drill[J]. International Journal of Advanced Manufacturing Technology,2012,59(5):617-622.
[26] CAI X J, QIN S, AN Q L, et al. Experimental analysis on delamination damage by acoustic emission in high speed drilling of carbon fiber reinforced plastics[J]. Key Engineering Materials,2013,589/590:287-292.
[27] HOCHENG H, TSAO C C. Computerized tomography and c-scan for measuring drilling-induced delamination in composite material using twist drill and core drill[C]//Proceeding of the First International Conference on Precision Engineering and Micro/nano Technology in Asia,2005.
[28] KOURRA N, WARNETT J M, ATTRIDGE A, et al. Metrological study of CFRP drilled holes with x-ray com puted tomography[J]. International Journal of Advanced Manufacturing Technology,2015,78(9/12):2025-2035.
[29] 陈昌华. 超声波显微镜在无损检测中的应用[C]//国际冶金及材料分析测试学术报告会,2008.
[30] 张厚江,陈五一,陈鼎昌. 声学显微镜用于碳纤维复合材料钻孔分层检测的研究[J]. 复合材料学报,1998,15(3):62-65.
[31] KILICKAP E. Optimization of cutting parameters on delamination based on Taguchi method during drilling of GFRP composite[J]. Expert Systems with Applications,2010,37(8):6116-6122.
[32] SHYHA I, SOO S L, ASPINWALL D, et al. Effect of laminate configuration and feed rate on cutting performance when drilling holes in carbon fibre reinforced plastic composites[J]. Journal of Materials Processing Technology,2010,210(8):1023-1034.
[33] FARAZ A, BIERMANN D, WEINERT K. Cutting edge rounding:An innovative tool wear criterion in drilling CFRP composite laminates[J]. International Journal of Machine Tools & Manufacture,2009,49(15):1185-1196.
[34] BABU J, SUNNY T, PAUL N A, et al. Assessment of delamination in composite materials:A review[C]//Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture,2015.
[35] RUBIO J C, ABRAO A M, FARIA P E, et al. Effects of high speed in the drilling of glass fibre reinforced plastic:Evaluation of the delamination factor[J]. International Journal of Machine Tools & Manufacture,2008,48(6):715-720.
[36] KARIMI N Z, HEIDARY H, MINAK G, et al. Effect of the drilling process on the compression behavior of glass/epoxy laminates[J]. Composite Structures,2013,98(3):59-68.
[37] NAGARAJAN V A, RAJADURAI J S, KUMAR T A. A digital image analysis to evaluate delamination factor for wind turbine composite laminate blade[J]. Composites Part B Engineering,2012,43(8):3153-3159.
[38] DEBNATH K, SINGH I, DVIVEDI A. Rotary mode ultrasonic drilling of glass fiber-reinforced epoxy laminates[J]. Journal of Composite Materials,2015,49(8):949-963.
[39] WANG Y Q, BAO Y J, GAO H. Studies on disfigurement-fee technology of drilling carbon fiber reinforced plastics[J]. Advanced Materials Research,2007,24/25:125-132.
[40] SALEEM M, BOUGHERARA H, TOUBAL L, et al. Analysis of stresses in CFRP composite plates drilled with conventional and abrasive water jet machining[J]. Materials Science Forum,2013,763:127-143.
[41] FUKUNAGA H, TAJIMA M, ATOBE S. 1503 Damage monitoring of CFRP structures based on impact force identification[C]//the Computational Mechanics Conference the Japan Society of Mechanical Engineers,2010.
[42] KIRKBY E, OLIVEIRA R D, MICHAUD V, et al. Impact localisation with FBG for a self-healing carbon fibre composite structure[J]. Composite Structures,2011, 94(1):8-14.
[43] 胡良志. 非连续碳纤维增强聚醚砜树脂基复合材料的制备工艺与力学性能研究[D]. 南京:南京理工大学,2014.
[44] 梅辉,成来飞,张立同,等. 2维C/SiC复合材料的拉伸损伤演变过程和微观结构特征[J]. 硅酸盐学报,2007,35(2):137-143.
[45] HUANG H, LI Z, CHENG H, et al. Stress distribution of CF/EP laminated composites under supercritical conditions[J]. International Journal of Polymer Science,2015(2):1-8.
[46] 唐国翌,闫允杰,陈锡花,等. 多向编织碳纤维复合材料的断裂及微观形貌[J]. 清华大学学报(自然科学版),1999,39(10):4-7.