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CFRP/Al stacks are commonly used in aerospace structure and drilling thousands of stack holes is quite an important assemble mission. However, the stack holds completely different material properties in upper and lower sides which makes it difficult to ensure drilling qualities. A step drill is reported to be suitable for drilling CFRP/Al stack and the point angle of the secondary cutting edge is the key parameter. This paper conducted an experimental study on this parameter to address the proper value for low-damage drilling of CFRP/Al stack. Five different point angles are employed, and the splintering of CFRP at drill entrance and the burr of Al at drill exit are analyzed. It is found that the splintering becomes serious with the angles increasing and the worst case occurs when the angle reached 160°; on the contrary, the burr height gradually decreased. The range of the point angle is suggested to be from 122° to 142° for balancing the drill-entrance and drill-exit qualities.
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