Methods for Reducing Interface Aperture Inconsistency During NC Orbital Milling of Aircraft Laminates with Coarse Pitch

The methods for reducing interface aperture inconsistency are studied in NC orbital milling(NCOM)of CFRP/Ti6Al4V laminates with coarse pitch.Comparative experiments show burr,aperture inconsistency and error are typical interface defects.Meanwhile,aperture inconsistency and error are more serious than burr in NCOM with coarse pitch.As one of the major causes of interface defects,axial force and radial force are intensively studied.Based upon the machining principle of orbital milling(OM)and the actual hole-making condition in laminated structures,NCOM experiments with coarse pitch are conducted on CFRP/Ti6Al4V laminates under different cutting conditions.Then,the effects of interlayer clamping,minimal quantity lubrication(MQL),twice milling instead of reaming,and interlayer speed change on interface aperture are analyzed.Research shows that interlayer clamping,interlayer speed change and MQL can effectively reduce out-of-tolerance of interface aperture.When making holes of different diameters with one cutter,axial feed has a greater effect on interface aperture precision than tangential feed.When making holes of the same diameter with different cutters,small diameter cutter will reduce interface aperture precision in a single processing.But the method of“twice milling instead of reaming”can improve the aperture precision effectively.

Parametric study on the axial performance of a fully grouted cable bolt with a new pull-out test

Modified cable bolts are commonly used in underground mines due to their superior performance in preventing bed separation when compared with plain strands. To better test the axial performance of a wide range of cable bolts,a new laboratory short encapsulation pull test(LSEPT) facility was developed. The facility simulates the interaction between cable bolts and surrounding rock mass,using artificial rock cylinders with a diameter of 300 mm in which the cable bolt is grouted. Furthermore,the joint where the load is applied is left unconstrained to allow shear slippage at the cable/grout or grout/rock interface.Based on this apparatus,a series of pull tests were undertaken using the MW9 modified bulb cable bolt.Various parameters including embedment length,test material strength and borehole size were evaluated. It was found that within a limited range of 360 mm,there is a linear relationship between the maximum bearing capacity of the cable bolt and embedment length. Beyond 360 mm,the peak capacity continues to rise but with a much lower slope. When the MW9 cable bolt was grouted in a weak test material,failure always took place along the grout/rock interface. Interestingly,increasing the borehole diameter from 42 to 52 m in weak test material altered the failure mode from grout/rock interface to cable/grout interface and improved the performance in terms of both peak and residual capacity.