Abstract
The effective design of tool geometry and optimization of process parameters play a pivotal role in mitigating damages such as tearing, burrs, and delamination during the drilling process of braided carbon fiber reinforced poly ether ether ketone (BCF/PEEK). This study introduces a novel method for selecting optimal drilling tools and damage prediction analysis in BCF/PEEK drilling. Firstly, a scale-span drilling finite element (FE) model is established based on the analysis of twist bit geometry and BCF/PEEK composition. Simulation and experimental validation identify damage causes in prefabricated holes. Subsequently, three innovative types of designed drilling tools are evaluated based on factors like hole morphology, thrust force, and delamination. Finally, Regression models are established to correlate damage factors, thrust force, and process parameters. The research findings indicate that the use of twist drill bits results in higher thrust forces, leading to delamination defects at hole exits. Conversely, employing a tapered drill-reamer could enhance the exit quality of prefabricated holes, consistently maintaining damage factors below 1.14 under identical process parameters. The proposed method effectively predicts the exceptional process parameters, with a maximum error of only 0.276% in the drilling of BCF/PEEK.