Investigating Fiber Chip Length Distribution and Morphology Analysis to Enhance Worker Safety and Recycling Efficiency in FRP Drilling

Abstract

Sharp fiber chips generated while drilling Fiber-Reinforced Polymers (FRP) can cause skin irritation and respiratory issues in workers. In addition, composite material waste often ends up in landfills, contributing to environmental contamination. This paper presents a novel simulation model designed to predict the fiber length distribution of drilling chips, aiming to reduce fiber dust and facilitate the reuse of short fibers. The model accounts for the drill tools' geometric structure and the materials' fiber orientations. The study clarifies the relationship between chip fiber length distribution, cutting conditions, and the drill's point angle. Geometric simulations demonstrate that tools with flat point angles and high feed rates can effectively increase chip fiber lengths.