Smart process parameters adaptation for drilling of CFRP and AA7075 stacks

This work explores a self-adaptive strategy for one-up drilling of CFRP/AA7075-T6 stacks, leveraging spindle active power monitoring for real-time parameter adjustments. The method enables precise detection of the material interface, ensuring optimal process conditions for each material without requiring additional sensors. Key quality metrics—burr height and delamination factor—were analysed under various switching conditions. Results reveal that switching parameters when the cutting edge fully engages the aluminium layer minimizes interface defects and enhances hole quality. The strategy proves superior to compromise parameter sets, reducing delamination in CFRP and burr formation in AA7075-T6, while maintaining productivity. This adaptive approach demonstrates high reliability and industrial applicability, offering significant improvements in hybrid material drilling for aerospace manufacturing.