JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 67

Drilling and trimming CFRP materials using a solid lubricant film

holes drilled from the back of the plate. The good side of the sample
plates were thus facing away from the drill. The SLE® was applied on the
good side before processing, so that the lubricating effect set after the
first drilling. The SLE® used had a thickness of 0.5 mm and a standard
adhesion named "DS". The interaction between the machine, the sample plate and the applied SLE® is shown in Figure 5. The investigation's
focus was to determine the maximum tool life per configuration, while
still guaranteeing a reasonable machining result. The individual processing results per configuration could be directly compared due to the four
intervals on the sample plate. During the visual inspection, the boreholes
were analysed and evaluated for delamination, fibre overhangs and outbreaks. As damage built up, the rating was adjusted so that a deterioration in quality would lead to appropriate rework or even rejects. All the
tools were tested and inspected up to a maximum of 1,000 holes, so any
short-term material or environmental effects would not result in premature termination of the trials. Figure 6 compares the last holes in the
series for the four different configurations. The four holes in the centre
represent the 1,000th hole of the configuration described for the respective segment. The comparison shows that in the processes without
SLE®, significant fibre overhangs and, in some cases, also delamination
occurred both in a coated and an uncoated tool. The machining quality
using SLE® and the same tool types was significantly better in both configurations, as no fibre overhangs remained. Since the processing result
still met the requirements in both configurations, it can be assumed that
the tools with SLE® could still be used, whereas the tools without SLE®
would have had to be exchanged well before the end of the test series.
An analysis of all the sample plates after completion of the evaluation
series showed that the tools without SLE® needed to be replaced much
earlier to ensure a sustainable component quality. For the four configurations, the following lifetimes were achieved:
-- 1,000 holes with non-coated drill bit with SLE®
-- 1,000 holes with coated drill bit with SLE®
-- 500 holes with non-coated drill bit without SLE®
-- 200 holes with coated drill bit without SLE®
The visual inspection of the drill holes shows that SLE® offers strong
deployment potential compared to processes without SLE®. An early
replacement of the tool increases the running tool costs and the process
auxiliary times, which is reflected in the overall operating result. If the
tools continue to be used, appropriate manual reworking is required, for
which employees and production areas are required. The SLE® sheet is
applied in one cycle before the machining process, but it contributes directly to the machining result, as shown in Figure 6.
Recommendations for the use of SLE® in machining
The use of SLE® should be reviewed in the form of a business case study
in order to validate the lifetime extension for the relevant case and to determine key economic figures. In many cases, the minimization of tooling costs results in a sustainable economic advantage through the use
of SLE®. In addition, the quality of the components is clearly improved
right from the start, which may be of particular interest for joining surfaces and visible edges. Here, the technical requirements outweigh the
economic aspects, and the use of SLE® can bring significant benefits in
both areas.
By minimizing manual reworking, SLE® is particularly suitable for are-

Fig. 6: Comparison of drill holes per configuration after 1,000 holes.
The 1,000th hole of each configuration is located inside the dotted square

as where reworking presents major technical and economic challenges.
The SLE® application time can be minimized by the trailing effect of
lubrication, as in some cases SLE® is applied on specific sections. As a
result, the trailing effect is exploited in the free areas. The best machining
result is achieved when the SLE® sheet is applied to the component from
both sides, so lubrication occurs at both the entry and exit. In this case,
it offers not only the pure lubrication advantage, but also an increased
surface tension, which counteracts uncut-fibres, delamination and fibre
breakouts.
Conclusion and next steps
Overall, the use of SLE® can contribute to enhanced performance during and after mechanical processing of CFRP materials. The surface
is protected by the SLE® sheet during processes such as trimming or
drilling and continues as a protection layer until the SLE® is finally removed. Surface scratches become unlikely and the edge quality is highly
increased, especially during an extended tool usage time before a tool is
changed. As shown in Figure 6, more than 1,000 drilling holes are possible with the same drill bit without losing cut quality.
This may significantly reduce drill bit changes, and therefore costs, as
well as the time needed for the exchange itself. Meanwhile, the preparation for the application of SLE® on the CFRP part can be done during
the machining of the previous part. The current development work focuses on the enhancement of the lubricant properties and reduced usage
of SLE®. This work is conducted in close correlation with the development/application of different adhesive tapes in order to increase the adhesive forces during machining together with fewer/more easily cleaned
residues on the surface after machining. As well as the possibility to use
technologies such as atmospheric pressure plasma or UV-laser pre-treatments for cleaning and activating the CFRP surface before subsequent
bonding or paint application.

N°131 November - December 2019

More information:
shigeru-horie@mgc.co.jp

/ jec composites magazine

67



JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019

Cover
Edito
Moving composites forward: Composites are blazing the trail
Contents
NEWS
In brief
Strategy
Agenda
BUSINESS
Asia - Continuous growth of the Asian composite markets
Startup - And the winner is...
JEC Asia - China’s EHang to take drones to mass production by 2020
MANUFACTURING
Life cycle management - New module for composite materials
Simulation - Designing CFRP structures with the aid of topology optimization
Recycling - lnnovative semi-products made of recycled carbon fibres
FEATURE AUTOMOTIVE - Do composites have an answer for everything?
Lightweighting - Roding Automobile GmbH uses advanced lightweight design software
Structure part - Thermally-conductive structural automotive compounds
Interior - A new material for thermoformed automotive interior applications
Cycle times - Fast-curing epoxy prepreg system for automated processes with short cycle times
Production - A revolutionary change in vehicle panel production featuring thermoplastic tape
Battery pack - A safer battery pack for e-vehicles using polyurethane pultrusion technology
Battery box - A lightweight solution for battery boxes
e-vehicle - The road to the 1000-kilometre electric vehicle
SOLUTIONS
Medical - The world’s lightest wheelchair made from graphene
Machine - Composites increase machine performance, operating speeds and accuracy
Material specification - Material specs for industrial applications of composite materials
Composites among us: security - When technical properties guarantee safety
TECHNOLOGY
Assembly - Drilling and trimming CFRP materials using a solid lubricant film
Inside the lab - Laboratory of ThermoStructural Composites
AFP - PAEK composite prepreg: fast and efficient part manufacturing
Index
Advertisers
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Cover
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 2
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Edito
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Moving composites forward: Composites are blazing the trail
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 5
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Contents
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 7
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - In brief
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 9
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Strategy
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 11
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 12
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Agenda
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 14
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Asia - Continuous growth of the Asian composite markets
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 16
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Startup - And the winner is...
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 18
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 19
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - JEC Asia - China’s EHang to take drones to mass production by 2020
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 21
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 22
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Life cycle management - New module for composite materials
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 24
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Simulation - Designing CFRP structures with the aid of topology optimization
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 26
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Recycling - lnnovative semi-products made of recycled carbon fibres
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 28
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 29
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 30
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 31
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Lightweighting - Roding Automobile GmbH uses advanced lightweight design software
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 33
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 34
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Structure part - Thermally-conductive structural automotive compounds
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Interior - A new material for thermoformed automotive interior applications
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 37
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Cycle times - Fast-curing epoxy prepreg system for automated processes with short cycle times
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 39
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 40
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Production - A revolutionary change in vehicle panel production featuring thermoplastic tape
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 42
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 43
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 44
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Battery pack - A safer battery pack for e-vehicles using polyurethane pultrusion technology
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 46
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 47
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Battery box - A lightweight solution for battery boxes
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 49
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - e-vehicle - The road to the 1000-kilometre electric vehicle
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 51
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 52
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 53
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 54
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Medical - The world’s lightest wheelchair made from graphene
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 56
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Machine - Composites increase machine performance, operating speeds and accuracy
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 58
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 59
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Material specification - Material specs for industrial applications of composite materials
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 61
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Composites among us: security - When technical properties guarantee safety
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 63
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Assembly - Drilling and trimming CFRP materials using a solid lubricant film
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 65
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 66
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 67
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Inside the lab - Laboratory of ThermoStructural Composites
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 69
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - AFP - PAEK composite prepreg: fast and efficient part manufacturing
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 71
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 72
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 73
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - Advertisers
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 75
JEC COMPOSITES MAGAZINE - Issue #131 - Novembre/December 2019 - 76
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