Research progress of laser drilling technology for carbon fiber reinforced composites
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摘要: 碳纤维增强树脂基复合材料(CFRP)具有抗疲劳性好、比强度高、耐热性好等优良的热物性能，已在航空、航天等领域得到广泛应用。作为主要的承力构件，CFRP板之间的机械连接所需加工的装配孔数量众多。然而，CFRP作为高硬度且各向异性的难加工材料，传统机械钻孔存在刀具磨损严重、制孔工序多等缺点；相比于机械钻孔，激光“不怕硬”，激光制孔无刀具磨损、经济性好、易于实现自动化控制。首先对CFRP激光制孔加工技术进行了综述，着重分析了CFRP激光制孔常见工艺；其次，剖析了CFRP激光制孔加工常见缺陷及其抑制研究现状；随后，阐述了CFRP激光加工工艺参数对制孔质量及效率的影响；为了阐明CFRP激光制孔材料移除机制，还综述了CFRP激光制孔加工数值仿真和基于高速摄像的加工过程动态观测研究进展；最后，展望了CFRP激光制孔技术的发展趋势。
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关键词:
- 碳纤维增强树脂基复合材料 /
- 激光制孔 /
- 制孔缺陷 /
- 工艺研究 /
- 数值仿真
Abstract: Due to its excellent thermal physical properties such as good fatigue resistance, high specific strength and good heat resistance, carbon fiber reinforced plastic composites (CFRP) have been widely used in rail transportation, aerospace, aircraft, etc. industries. As the main load-bearing parts, a large number of assembly holes need to be machined for the mechanical connection between CFRP plates. However, as a hard-to-machining material with high hardness and anisotropy, traditional mechanical drilling has many disadvantages, such as many drilling procedures, serious tool wear and so on. Compared with the traditional mechanical drilling process, the laser can machine any hardness materials, and laser drilling shows the advantages such as no tool wear, good economy and easy to realize automatic control. First, this paper summarized the laser drilling technology of CFRP plates, and the common processes of laser drilling CFRP were emphatically analyzed. Then, the research status of defects and their suppression in CFRP laser drilling was analyzed. Subsequently, the influences of laser processing parameters on CFRP processing quality and efficiency were discussed. Aiming to reveal the material removal mechanism of laser drilling CFRP, the numerical simulation and dynamic process observation based on high-speed camera were emphatically analyzed. Finally, the development trends of CFRP laser drilling technology were forecasted. -
图 2 同轴环制孔工艺示意图
Figure 2. Schematic description of coaxial-trepan drilling process
d—Interval distance; Spp—Interlaced spacing; Rmin—Minimum of radius; Rmax—Maximum of radius
图 3 双光束制孔工艺：(a)工艺示意图；(b)制孔横截面形貌
Figure 3. Schematic diagram of dual-beam laser drilling process: (a) Process diagram; (b) Cross section morphology of drilled hole
d0, d1—Distance
图 4 螺旋制孔工艺：(a)激光束旋转原理；(b)加工不同形状孔；(c)旋切头内置光路及相关部件
Figure 4. Helical drilling process: (a) Principle of laser beam rotation; (b) Types of drilling holes produced by helical drilling; (c) Internal optical path and related components of rotary laser cutting head
f—Focal length; a—Eccentric distance
图 5 “双旋转”制孔工艺示意图
Figure 5. Schematic diagram of double-rotation drilling process
R—Rotation radius; r—Beam radius; v—Rotation speed
图 7 CFRP制孔工艺锥度对比：(a)同轴环制孔工艺；(b)螺旋制孔工艺
Figure 7. Hole taper comparison of CFRP for different laser drilling processes: (a) Coaxial-trepan drilling process; (b) Helical drilling process
Din—Inter size; Dout—Outlet size
图 8 CFRP双旋转制孔：(a)孔形貌；(b)孔入口尺寸；(c)孔出口尺寸
Figure 8. Double-rotation drilling process for CFRP: (a) Hole morphology; (b) Inlet dimension of the hole; (c) Outlet dimension of the hole
图 10 激光/机械加工CFRP板拉伸断裂界面和力学特性：(a) 机械加工后拉伸失效断面形貌；(b) 激光加工后拉伸失效断面形貌；(c)疲劳裂纹扩展；(d) 样件刚度降解
Figure 10. Tensile fracture section and mechanical properties of laser/mechanical drilling of CFRP plates: (a) Morphology of tensile failure section after mechanical processing; (b) Morphology of tensile failure section after laser processing; (c) Fatigue crack propagation; (d) Stiffness degradation of the sample
σUTS—Ultimate tensile strength
图 11 激光双旋转制孔和机械钻孔拉伸力学特性对比
Figure 11. Comparison of tensile mechanical properties between double rotation drilling and mechanical drilling
图 12 CFRP激光加工热影响区(HAZ)损伤：(a)损伤定义；(b)孔口HAZ
Figure 12. Heat affected zone (HAZ) damage in CFRP laser processing: (a) Definition of damage; (b) HAZ of the hole inlet
Di—Exposed length; Vs—Cutting velocity
图 13 CFRP激光制孔加工HAZ：((a)~(b)) 孔入口HAZ尺寸；((c)~(d)) 孔出口HAZ尺寸
Figure 13. HAZ of CFRP laser drilling: ((a)-(b)) HAZ on the inlet edge; ((c)-(d)) HAZ on the outlet edge
图 15 紫外和红外激光加工CFRP材料移除模型
Figure 15. Ablation model of CFRP laser processing by UV and IR laser
图 16 CFRP激光加工数值仿真：(a) 激光与CFRP单层碳纤维作用示意图；(b) 孔周边碳纤维膨胀现象；(c) 不同环间距下CFRP材料移除深度预测
Figure 16. Numerical simulation of laser machining CFRP: (a) Schematic of CFRP interaction process on a single carbon fiber layer; (b) Fiber expansion around the processed hole; (c) Predicted material removal depth for various values of spacing distance
$\ell _{\rm{Proc}} $—Processing depth
图 17 CFRP激光制孔锥度成型：(a)仿真；(b)实验
Figure 17. Taper of CFRP laser drilling process: (a) Simulation; (b) Experiment
图 18 CFRP激光加工过程羽烟和等离子体观测:(a)羽烟流动；(b)等离子体溅射
Figure 18. Observation images of plasma and plume formation during laser processing CFRP: (a) Plume flowing; (b) Jetting of plasma
XM—Distance of compression wave
表 1 CFRP激光制孔常见工艺
Table 1. Common processes of CFRP laser drilling
Drilling process Thickness of plate Drilling diameter Taper of drilled hole HAZ of drilled hole Drilling efficiency Coaxial-trepan drilling Thin Large Large Large Low Dual-beam drilling High Large Large Small Medium Helical drilling Medium Small Small Medium high Double-rotation drilling Medium Medium Small Medium high 
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