Research progress of cutting force modeling for drilling carbon fiber reinforced plastics/light alloy laminated structure parts

Carbon fiber reinforced plastics/light alloy laminated structural parts have become the first choice for key load-bearing structural parts in the aerospace field due to their high specific strength, high specific modulus and high fracture toughness. In order to ensure the processing efficiency and hole-making quality of the overall structural parts, it is urgent to carry out integrated hole-making processing for laminated structural parts. However, carbon fiber reinforced plastics, light metals and their laminated interfaces are discontinuous, heterogeneous and anisotropic, which makes the high-efficiency and low-damage precision machining of laminated structures a technical difficult problem. The cutting force is closely related to the parameters of geometry, kinematics, mechanics and dynamics of laminated structures, which can directly reflect the action law between the processing parameters and the hole quality. Therefore, the cutting force prediction model, which created by analyzing the mechanical behavior of tools and workpieces at different scales, is very important to clarify the removal mechanism of the laminated structure and further improve the quality of integrated drilling of laminated structural parts. Based on this, firstly, the influence of each component structure and material characteristics, tool geometry, cutting kinematics and drilling system on the chip forming process during the drilling process of laminated structural parts is analyzed, and the material removal mechanism of the cutting process of laminated structural parts is revealed. Secondly, the research status of the cutting force model for the integrated drilling of laminated structural parts is systematically summarized. The relevant modeling methods of the analytical model are elaborated from the five important aspects of classical cutting force model, tool discretization model, cutting amount calculation, dynamic cutting angle calculation and drilling stage division. Furthermore, the application of other cutting force models such as empirical model, finite element model and intelligent model in the integrated drilling of laminated structure is comprehensively analyzed. The material removal mechanism and cutting force characteristics of ultrasonic assisted drilling are analyzed from the perspectives of tool trajectory, undeformed chip thickness and chip forming. Finally, the potential research difficulties and development trends are analyzed for the removal mechanism and cutting force model of the integrated drilling process of laminated structures, in order to further improve the low-damage cutting criterion of laminated structures and establish the theoretical framework of chip formation theory for integrated drilling processing so as to promote the development of cutting force model.