Drilling performance of small holes on Cf/SiC composites with brazed diamond grinding rods.

Carbon fiber reinforced silicon carbide matrix composites (Cf/SiC composites) are lightweight, high strength, wear-resistant, and heat-resistant, making them widely used in aerospace and other industries. However, machining holes in Cf/SiC composites is a great challenge due to the anisotropy and high hardness of the material. In this paper, a brazed diamond grinding rod was employed to grind 1 mm diameter holes in Cf/SiC composites, and the influence of grinding parameters on grinding force, hole entrance/exit defects, and hole wall quality was investigated. In addition, the material removal mechanism of Cf/SiC composites and the wear mechanism of the diamond grinding rod were explored. The findings showed that the damage at the hole entrance and exit predominantly manifests as tearing and burring. The damage factor at the hole exit is 3.5% larger than that at the hole entrance, and the damage factor at both the hole entrance and exit reduces with the growth of spindle speed and the decrease of feed rate. In addition, the diameter errors of the hole entrances and exits are all less than 10%, and the entrance diameter is 2.9% larger than the exit. The hole wall defects include fiber fracture, silicon carbide matrix peeling, and inherent porosity, with poorer surface quality at fiber orientation angles (FOA) of 90° to 180°. The main wear mechanisms were identified as abrasive wear and the spalling of abrasive grains. [ABSTRACT FROM AUTHOR]