Effect of Cutting Conditions on Surface Integrity when Robotic Drilling of Aluminum 6082-GFRP Stacks

Six-axis robots are increasingly employed in manufacturing due to their excellent volume on cost ratio and extensive reach, facilitating the machining of large components, including those made of composites. However, this enhanced volume on cost ratio often compromises rigidity. This study investigates the effect of cutting conditions on surface integrity and robotic drilling forces when machining Aluminum 6082-GFRP stacks using 6 mm solid carbide drills and a 6-axis Stäubli TX200 robot. Two distinct drill geometries are assessed in various drilling sequences. Feed rate emerges as a pivotal parameter affecting drilling forces and hole quality. Comprehensive testing encompasses a range of feed rates and drilling strategies in both individual materials and stack sequences. The analysis includes cutting forces and hole quality, considering surface integrity and standard quality indicators such as delamination, arithmetic roughness, and burr height. The research seeks to propose optimal cutting conditions, specifically feed rate and cutting speed, essential for advanced industrial applications. These conditions ensure hole quality and surface integrity, which is particularly important for riveting processes and ensuring effective sealing.