1 N.S. Mohana,, S.M.

Delamination analysis in drilling Journal of Materials

Kulkarni , A. process of glass fiber reinforced plastic Processing Technology
Ramachandra (GFRP) composite materials 186 (2007) 265–271
ELSEVIER
Abstract
Machining processes are generally used to cut; drill, or contour composite laminates for building
products. In fact, drilling is one of the most commonly used manufacturing processes to install fasteners
for assembly of laminate composites. The material anisotropy resulting from fiber reinforcement heavily
influences the machinability during machining. Machining of fiber reinforced plastic (FRP) components
is often needed in spite of the fact that most FRP structures can be made to near-net shape and drilling
is the most frequently employed secondary machining process for fiber reinforced materials. Therefore,
the precise machining needs to perform to ensure dimensional stability and to obtain a better
productivity of the component. The drilling parameters and specimen parameters evaluated were speed,
feed rate, drill size and specimen thickness. A series of experiments were conducted using TRIAC VMC
CNC machining center to machine the composite laminate specimens at various cutting parameters and
material parameters. The measured results of delamination at the entry and exit side of the specimen
were measured and analyzed using commercial statistical software MINITAB14. The experimental
results indicated that the specimen thickness, feed rate and cutting speed are reckoned to be the most
significant factors contributing to the delamination. A signal-to-noise ratio is employed to analyze the
influence of various parameters on peel up and push down delamination factor in drilling of glass fibre
reinforced plastic (GFRP) composite laminates. The main objective of this study is to determine factors
and combination of factors that influence the delamination using Taguchi and response surface
methodology and to achieve the optimization machining conditions that would result in minimum
delamination. From the analysis it is evident that among the all significant parameters, specimen
thickness and cutting speed have significant influence on peel up delamination and the specimen
thickness and feed have more significant influence on push down delamination. Confirmation
experiments were conducted to verify the predicted optimal parameters with the experimental results,
good agreement between the predicted and experimental results obtained to be of the order of 99%.

Keywords: Glass fiber reinforced thermoplastics; Thermoset plastics; Delamination; Contact moulding;
Design of experiments; Taguchi,RSM, ANOVA

Conclusions
From the analysis of results in drilling of GFRP composite plates using conceptual S/N ratio approach,
ANOVA and response surfaces, the following can be concluded from the present study within the range
of the experiments.
(1) As seen in this study, the Taguchi method provides a systematic and efficient methodology for the
design optimization of the process parameters resulting in the minimum delamination
with far less effect than would be required for most optimization techniques.
(2) Based on the S/N, the optimal parameters for the minimum peel up delamination are the feed rate at
level 1 (50 mm/min), the cutting speed at level 3 (1200 rpm), drill tool diameter at level 2 (6 mm) and
the material thickness at level 4 (12 mm).
(3) Similarly, the optimum parameters for the minimum push down delamination are the feed rate at
level 1 (50 mm/min), the cutting speed at level 1 (600 rpm), drill tool diameter (10 mm), and the material
thickness at level 3 (10 mm).
(4) The feed rate, cutting speed and material thickness are seen to make the largest contribution to the
delamination effect. Generally, the use of high cutting speed and low feed favor the minimum
delamination on both entry and exit of the drilling leads to better surface finish and tool life.
(5) The feed rate influences the push down and peel up delaminations next to the material thickness.
Therefore, the feed rate seems to be the most critical parameter and should be selected carefully in order
to reduce all kinds of damages.
(6) Conceptual S/N ratio andANOVAapproaches for data analysis draw similar conclusion.
(7) The confirmation experiments were conducted to verify the predicted optimal parameters with the
experimental results. The comparison of the predicted delamination factor with the experimental values
of delamination factors using the optimal cutting parameters, good agreement between the
predicted and experimental results of order of 99% being observed.
(8) Response surface analysis reveals the minimum peel up delamination at the low level of feed rate,
at the high level of material thickness and medium level of cutting speed. Similarly, for the minimum
push down delamination is observed at low level of feed rate, at high level of cutting speed and medium
level of drill bit diameter and material thickness.
2 U.A. Khashaba Delamination in drilling GFR- Composite Structures
thermoset composites 63 (2004) 313–327
ELSEVIER
Abstract:-
Delamination is a major problem associated with drilling fiber-reinforced composite materials that, in
addition to reducing the structural integrity of the material, also results in poor assembly tolerance and
has the potential for long-term performance deterioration. Delamination-free in drilling different fiber
reinforced thermoset composites is the main objective of the present paper. Therefore the influence of
drilling and material variables on thrust force, torque and delamination of GFRP composites was
investigated experimentally. Drilling variables are cutting speed and feed. Material variable include
matrix type, filler and fiber shape. Drilling process was carried out on cross-winding/polyester,
continuous-winding with filler/polyester, chopped/polyester, woven/ polyester and woven/epoxy
composites. A simple inexpensive accurate technique was developed to measure delamination size. The
results show that the presence of sand filler in continuous-winding composites not only raised the values
of cutting forces and push-out delamination but also increased their values with increasing cutting speed.
In contrast, increasing the cutting speed in drilling cross-winding, woven and chopped composites
reduces the push-out delamination as a result of decreasing the thrust force. The thrust forces in drilling
continuous-winding composite are more than three orders of magnitude higher than those in the cross
winding composites. Chopped composites have lower push-out delamination than those made from
woven fibers. For the same fiber shape, the peel-up and push-out delaminations of woven/epoxy
composite are lower than that for woven/polyester composites. Delamination, chipping and spalling
damage mechanisms were observed in drilling chopped and continuous-winding composites. In drilling
woven composites the delamination was observed at different edge position angles due to the presence
of the braids that made by the interlacing of two orthogonal directions of fibers tows (warp and fill).
Delamination-free in drilling cross-winding composites was achieved using variable feed technique.

Keywords: Composites; Filler; Chopped fiber; Woven fiber; Polyester; Epoxy; Thrust; Torque;
Drilling; Feed; Speed; Peel-up delamination; Push-out delamination

Conclusions
1. The constituent materials of the composite specimens, specimen thickness and machining time have
a significant effect on the behavior of thrust force and torque over the machining time. At minimum
cutting variables the thrust force of continuous winding, woven/epoxy and chopped composites were
suddenly dropped from the maximum value to zero at the drill exit with significant push-out
delamination. On the other hand gradual decreases in thrust force was observed for cross-winding
composites resulting in delamination-free at drill exit.
2. The presence of sand filler in continuous-winding composites not only raised the values of cutting
forces and push-out delamination but also increased their values with increasing cutting speed. In
contrast, increasing the cutting speed in drilling cross-winding, woven and chopped composites reduces
the push-out delamination as a result of decreasing the thrust force. The thrust forces of continuous-
winding composite are more than three orders of magnitude higher than those in the cross-winding
composites.
3. The perpendicularity of weft and fill fibers in woven composites makes each cutting edge met at least
four tangential fiber directions per one revolution. Two for the warp fibers at edge position angle equal
0_ and 180_ and two for the fill fibers at edge position angle equal 90_ and 270_. These fibers are
loaded compressively resulting in higher torque than chopped composites, which made from the same
matrix.For the same fiber shape (woven) the matrix has insignificant effect on thrust force. In contrast
the torque of woven/polyester composites is higher than that for woven/epoxy composites.
4. The effect of cutting speed on peel-up delamination is contrary to push-out delamination for
polyester-basecomposites (continuous-winding, cross-winding, and woven/polyester composites).
While the peel-up and push-out delaminations of woven/epoxy composite were decreased with
increasing cutting speed. The delamination size was increased with increasing feed as a result of
increasing thrust force. The delamination associated with push-out is more severe than that of peel-up.
5. For the same fiber shape, the peel-up and push-out delaminations of woven/epoxy composite are
lower than that for woven/polyester composites despite the two composites have a proximately equal
thrust forces. Although chopped composites has higher thrust force than woven composites it has lower
push-out delamination than woven composites.
6. Delamination, chipping and spalling damage mechanisms were observed in drilling chopped and
continuous-winding composites. In drilling woven composites the delamination was observed at
different edge position angles.
7. Delamination-free in drilling cross-winding composites was achieved using variable feed technique.
This technique can be applied to the other composite materials after selecting the optimum cutting
variables,from the experimental results, that prevent the delamination around the drilled holes.
8. Accurate inexpensive technique for measurement the delamination size within 10_3 mm resolution
has been developed.
3 A.M. Abr˜ao , P.E. Faria , Drilling of fiber reinforced plastics: A Journal of Materials
J.C. Campos Rubio, P. review Processing Technology
Reis , J. Paulo Davim 186 (2007) 1–7
ELSEVIER
Abstract
The use of polymeric composite materials has increased considerably over the last decade and, as a
consequence, the number of papers focused on relevant aspects concerning the machinability of such
materials has also increased. The principal aim of this work is to present a literature survey on the
machining of composite materials, more specifically on drilling of glass and carbon fibre reinforced
plastics. Aspects such as tool materials and geometry, machining parameters and their influence on the
thrust force and torque are investigated. Additionally, the quality of the holes produced is also assessed,
with special attention paid to the delamination damage. The results indicated that despite the fact that
some aspects, such as the effect of cutting parameters and tool geometry on the quality of the hole have
been extensively studied over the last years, the phenomena associated to shearing of polymeric
composite materials require additional studies in order to allow a better understanding of the behaviour
of this category of materials when subjected to cutting.

Keywords: Drilling; Taguchi, Polymer-matrix composites; Thrust force; Delamination

Concluding remarks
The following conclusions can be drawn with regard to the drilling of polymeric composite materials:
• Firstly, this manufacturing process is concerned with two principal applications: production of
components for the transportation industry (mainly aeronautic but also naval and automotive industries)
and components for the electronic industry (more specifically printed wiring boards).
• Considerable efforts have been focused on the better understanding of the phenomena associated to
the cutting mechanism. As far as the work material is concerned, glass and carbon fibre reinforced
composites have been equally investigated, however, epoxy resin is preferred as the matrix material.
Conventional high speed steel twist drill are used as much as cemented tungsten carbide drills, however,
it seems to be an agreement among the authors on the necessity of developing tools with special
geometry in order to achieve best performance.
• The principal factors used to evaluate the performance of the process are undoubtedly the damage
caused at the drill entry or exit and the roughness on the wall of the hole produced. In spite of the fact
that this damage is frequently measured in terms of delamination, techniques employed to measure the
effect of the cutting parameters cutting speed (usually indicated as rotational speed) and feed rate on
this damage differ considerably: while a group of researchers tend to measure the damage directly (using
parameters such as damage width, delaminated area or delamination factor), a second group of authors
measure the damage indirectly through thrust force, torque or power.
• Another point of agreement among the authors is the need of developing devices and/or procedures in
order to allow the reduction of the damaged area without the need of a backing material, which makes
the drilling operation longer and dearer.

4 I. Singh · N. Bhatnagar Drilling of uni-directional glass fiber Int J Adv Manuf

reinforced plastic (UD-GFRP) Technoly
composite Laminates (2006) 27: 870–876
springer
Abstract
Drilling of fiber reinforced plastic (FRP) composite materials is a field open to a plethora of questions.
Drilling induced damage is a research area that has not been explored exhaustively. The present research
endeavor is an effort to correlate drilling-induced damage with drilling parameters. Tool point geometry
is considered a major factor that influences drilling induced damage. Experiments were conducted and
drilling induced damage was quantified using the digital image processing technique. The results also
reestablished the cutting speed to feed ratio as an important variable that influences drilling induced
damage. Mathematical models for thrust, torque, and damage are proposed that agree well with the
experiments.

Keywords Cutting forces · Damage · Drilling · GFRP

Conclusions
The research interest in the present study was to investigate the influence of drilling parameters on the
cutting forces and drilling-induced work material damage for various drill point geometries. It is
concluded that:
• Higher thrust and the torque values are recorded for the 4- facet drill point geometry and therefore the
4-facet drill is not recommended for drilling laminated UD-GFRP composites.
• The thrust and torque responses are lower for 8-facet and Jodrill than the other two geometries for
which mathematical thrust and torque models are proposed.
• Drilling-induced damage shows an elliptical zone with the major axis of the ellipse lying in the
direction of the fibers.
• Drilling-induced damage depends on the speed/feed ratio, giving maximum value at higher cutting
speeds.
• A new quantified mathematical damage model for four drill geometries correlating the damage area
ratio (Da/Ha) with the operating variables viz. cutting speed and the feed speed are proposed.
• Validation of models give an error of 10% between the theoretical and experimental values for 8-facet,
Jodrill, and parabolic points and 20% for the 4-facet drill point geometry.
• Contrary to the general belief, drilling-induced damage does not correlate with the thrust force trends
for all the drill geometries; however, it matches with the torque trend and therefore it can be inferred
that the theoretical models assuming thrust as the main contributor of damage is not correct and may
lead to ambiguous algorithm development.
• Thrust force models must be applied with caution and with certain limitations for predicting drill-
induced damage.
5 U.A. Khashaba, I.A. El- Drilling analysis of woven glass fiber- Journal of Composite
Sonbaty, A.I. Selmy and reinforced/epoxy composites Materials
A.A. Megahed 0(0) 1–15
Sage Publication

Abstract
This article deals with the effect of drilling parameters (feed, speed, and drill pre-wear) on the
machinability parameters(thrust force, torque, peel-up and push-out delaminations, surface roughness,
and bearing strength) in drilling woven glass fiber-reinforced. The results show that at high feeds (0.45
mm/rev), the drill point acts as a punch that pierces the laminate with approximately constant push-out
delamination size irrespective to the value of the thrust force. Surface roughness increases with the
increase of drill pre-wear due to the generated heat that assisted by the low thermal properties of
polymeric composites. Drilling at high feeds reduces the stiffness of the specimens and its ultimate
bearing loads. Artificial neural network and multivariable regression models were developed for
predicting the bearing strength of drilled holes.
Keywords
Composites, drilling, drill pre-wear, thrust force, torque, delamination, surface roughness, bearing
strength, neural networks

Conclusions
An experimental investigation was implemented to evaluate the effect of drilling parameters (feed,
speed, and drill pre-wear) on the machinability parameters (thrust force, torque, peel-up and push-out
delaminations,surface roughness, and bearing strength) in drilling GFRE composites. ANNs and MVR
models were developed for prediction of the machinability parameters of the drilled holes. The results
show that the behavior of thrust force during drilling process was greatly affected by the drill pre-wear.
This effect becomes more significant at high-cutting speed and feed, which in turn increases peel-up
and push-out delaminations. At high feeds (0.45 mm/revolution), the drill point acts as a punch that
pierces the laminate, instead of cutting through it, with approximately constant push-out delamination
size irrespective to the value of the thrust force. Drilling at high speeds and drill pre-wear results in high
surface roughness due to the generated temperature that is assisted by a low-coefficient of thermal
conduction and a low-transition temperature of GFRE composites. In addition, the increasing of thrust
force as a result of increasing drill pre-wear leads to destruction of the fiber/matrix interfaces and
successive deterioration of the surface finish. The partially sheared fibers due to the abrasion action of
the pre-wearied drill point are another reason for the increasing of surface roughness.
6 Nilanjan Das ,Chakladar Drilling of woven glass fiber- Int J Adv Manuf
& Surjya K. Pal & reinforced plastic—an experimental Technol
Parthasarathi Mandal and finite element study (2012) 58:267–278
SPRINGER

Abstract
Drilling in woven fiber-reinforced plastics is a well-known practice in modern-day manufacturing. The
high fracture toughness of woven fiber-based composites over unidirectional counterparts is increasing
demand in aviation and electronics industries. Hence, failure of these materials at harsh environments
is a matter of concern. Very few numerical studies on drilling of these composites have been carried
out; hence, the present scope may be considered as a trial de novo. Delamination was studied in the
present work at different feed– speed combinations. Drilling responses were estimated using finite
element as a numerical simulation tool. An equivalent elastic macromechanical model was assumed
for the woven composite workpiece. A 3D drill bit was modeled using commercial CAD package Pro-
Engineer and Ansys Autodyn was used as the solver environment. The simulation and validation
experiments were carried out at planned feed–speed combinations. The effect of process parameters on
exit and entry delamination is also documented. The thrust determined by finite element techniques
showed good prediction with the experimental results.

Keywords Glass fiber-reinforced polymer (GFRP) . Drilling . Delamination, ANSYS

Conclusion and future scope

Among 16 holes drilled in the workpiece with HSS drill bit, the holes for Vc=45 and 65 m/min with
same feed of 0.25 mm/rev showed minimum delamination (peel-up and push-out). But the rest from
feed 0.5–1.0 mm/rev showed significant changes indicating that the tool has already started to wear;
i.e., if a fresh drill bit is able to make a single hole, then the number of drills required is equal to the
number of holes to be drilled or number of times the tool has to be reground. The rest 16 holes drilled
with carbide drill bit showed comparatively less delamination than with HSS due to reduced thrust at
same feed–speed combinations. High fracture toughness of work material has become the key reason
behind drill wear, specifically at chisel edge which ultimately aggravates delamination and hence
strength of the work material. So the present scope is a forerunner in achieving the same goal but for
woven composites. Though as a whole, the finite element analysis of drilling woven composites is
highly complicated, the element shape function and the boundary conditions are simplified to save
computation time. The motion constraints to workpiece and tool are kept as in experimental setup. A
near-accurate 3D drill model has been developed based on available drill grinding techniques. The
material model has been considered elastic which accounts to a close estimate of thrust within about
80–90% of the experimental values. An equivalent macromechanical model has been represented for
the composite material which is sufficient to investigate the drilling responses. The ANP technique as
finite element solver is found to work well with the present nonlinear analysis. As the material model
is assumed as elastic, cutting action could not be predicted. Elastoplastic material model is essential to
simulate actual cutting and chip formation finally leading to modeling of delamination. Softwares like
Ultimatte AdvantEdge do simulate such elastoplastic deformation mechanisms but presently for metals.
Hence, modeling such deformation problems can be accounted in future with proper subroutines to take
care anisotropic failure phenomenon. Since the drill is considered rigid in the present study, the elements
meshing the drill help only to compute mass inertia for finite element analysis. The drill profile acts
only as a displacement field hence constitutive properties are not required. Modeling drill wear with
deformable tool will include constitutive properties that can be kept as future scope.

7 R. Vimal Sam Singh, Modeling and Analysis of Thrust Force International Journal of
B.Latha, and and Torque in Drilling GFRP Recent Trends in
V.S.Senthilkumar Composites by Multi-Facet Drill Using Engineering
Fuzzy Logic Vol. 1, No. 5
Abstract—
Glass fiber reinforced plastics are finding increased applications in various engineering fields such as
aerospace, automotive, electronics and other industries. Drilling is one of the most frequently practiced
machining processes in industries owing to the need for component assembly in mechanical structures.
In this work, experiments were conducted using 8 Facet Solid Carbide drills based on L27 Orthogonal
Array. The process parameters investigated are spindle speed, feed rate and
drill diameter. Fuzzy rule based model is developed to predict thrust force and torque in drilling of
GFRP composites. The results indicated that the model can be effectively used for predicting the
response variable by means of which delamination can be controlled.

Index Terms— GFRP Composites, Drilling, Delamination, Fuzzy logic, Thrust force, Torque, Taguchi,
Orthogonal Array

CONCLUSIONS
The thrust force and torque developed during drilling of GFRP composites has been investigated
according to the L27 orthogonal array experiments. Fuzzy rule based model has been developed for
predicting thrust force and torque in drilling of GFRP composites. Based on the experimental and fuzzy
modeling results, the following conclusions are drawn:
1. Rule based fuzzy logic model for thrust force and torque is developed from the experimental data.
The predicted fuzzy output values and measured values are fairly close to each other, which indicate
that the fuzzy logic model can be effectively used to predict the thrust force and torque in drilling GFRP
composites.
2. The verification results reveal that the fuzzy rule based model is suitable for predicting the thrust
force and torque in drilling of composites.
3. Utilization of this system can improve the quality of drilled part; if online monitoring is introduced.
This system can reduce the tedious model making, computational cost and time.
4. Further improvement of model can be possible by introducing more number of variables and wider
range of cutting conditions.

8 N. S. MOHAN Machining of Fiber-reinforced Journal of

Thermoplastics: Influence of Feed REINFORCED
and Drill Size on Thrust Force PLASTICS AND
and Torque during Drilling COMPOSITES
Vol. 24, No. 12/2005
Sage Publication
ABSTRACT:
Polymer-based composite materials possess superior properties such as high strengthto- weight ratio,
stiffness-to-weight ratio, and good corrosive resistance and therefore, are preferred for high-
performance applications such as in the aerospace, defense, and sport goods industries. Drilling is one
of the indispensable methods for building products with composite panels. Drilling tests have been
conducted on glass fiber-reinforced plastic composite GFRP laminates using an instrumented CNC
milling center. Machining parameters such as drill size, feed rate, and cutting speed have been observed
for damage-free drilling of GFRP materials. A series of drilling experiments have been conducted on
glass fiber-reinforced polyester laminates and the responses experienced such as thrust force and torque
as functions of feed rate and drill size have been characterized to develop a semiempirical relationship
which correlated well with an established model in terms of cutting parameters. Results indicated that
experimental values correlated better with the model of thrust for 6mm drill size than for 10mm and
torque correlated better for lower feed ranges than for the higher feed ranges.

KEY WORDS: glass fiber-reinforced thermoplastics, drilling thrust and torque, specific cutting
energy, contact molding

CONCLUSIONS

An experimental study was performed to determine the influence of feed rate and drill diameter on the
machining output characteristics like thrust and torque. The experimental results agree well with the
empirical relation arrived through the dimensional analysis of the drill torque and thrust as functions of
feed rate and drill diameter. A nonlinear relationship was observed to exist between the drilling
force/torque and drilling parameters such as drill diameter and feed. Consistency was observed in these
results since they were obtained from the experiments which appropriately described the drilling of
composite materials. It could be seen that the thrust and torque resulting from empirical relations show
a good agreement with the experimental data, in the feed range of 0.1–0.5 mm/rev. The error distribution
of thrust and torque for both the drill sizes showed similar trend and therefore, indicates the validity of
the empirical relationships. The methodology described in this research can be extended to a large
number of composite systems and various material parameters.
9 B. Latha , V. S. MODELING AND OPTIMIZATION OF Machining Science and
Senthilkumar & K. PROCESS PARAMETERS FOR Technology
Palanikumar DELAMINATION IN DRILLING GLASS 15:172–191
FIBER REINFORCED PLASTIC (GFRP) Taylor & Francis
COMPOSITES
Abstract
Glass fiber-reinforced composite materials are used in varieties of applications due to their excellent
properties. Drilling is an indispensable process for this kind of materials. Delamination due to drilling
is an important concern and is to be reduced. In the present work, drilling tests were carried out on
computer numeric control (CNC) drilling machine. The parameters considered for the drilling
investigations were spindle speed, feed rate and diameter of the drill bits. Multiple
regression analysis is used for the modeling of process parameters in drilling of GFRP composites.
Taguchi’s S=N ratio analysis and desirability-based approach are used for the optimization of process
parameters for studying the delamination in drilling of GFRP composites. The results revealed that the
factor feed rate and drill diameter are the most influential parameters which affects the delamination in
drilling of GFRP composites. The interaction between the parameters
also affects the delamination in drilling of GFRP composites.

Keywords
delamination, desirability-based approach, drilling, GFRP composites, multiple regression analysis,
Taguchi method

CONCLUSION
Experiments are conducted on CNC machining centre for analyzing the delamination in drilling of
GFRP composites. Taguchi’s method and multiple regression analysis are used for modeling and
analysis of delamination in drilling of GFRP composites. Based on the experimental results and
analysis, the following conclusions are drawn:
1. Multiple regression analysis is used for modeling the drilling parameters on drilling of GFRP
composites. The predicted output values and experimental values are fairly close to each other, which
indicate that the response surface model can be effectively used to predict the delamination factor in
drilling of GFRP composites.
2. The optimal results are achieved through Taguchi’s S=N analysis and desirability- based approach.
The verification results indicated that the optimal drilling parameters really reduce the delamination in
drilling of GFRP composites.
3. ANOVA results revealed that the factor f (feed rate) and factor d (drill diameter) are the most
influential parameters which affects the delamination in drilling of GFRP composites. The combination
of spindle speed and feed rate also affects the delamination in drilling of GFRP composites.
4. Verification test results reveal that the response surface model and optimization studies used in this
work is very much suitable for predicting and optimizing the delamination factor in drilling of
composites.
5. Further improvement of model can be possible by introducing more number of variables and wider
range of cutting conditions.
10 E. Kilickap Optimization of cutting parameters on Expert Systems with
delamination based on Taguchi method Applications
during drilling of GFRP composite 37 (2010) 6116–6122
ELSEVIER
Abstract
Drilling of glass fibre reinforced plastic (GFRP) composite is substantially different from metallic
materials due to its mechanical properties. The drilling of this material may generate delamination of
drilled holes on workpiece. The purpose of this paper is to investigate the influence of the cutting
parameters, such as cutting speed and feed rate, and point angle on delamination produced when drilling
a GFRP composite. The damage generated associated with drilling GFRP composites were observed,
both at the entrance and the exit during the drilling. Hence it is essential to obtain optimum cutting
parameters minimizing delamination at drilling of GFRP composites. Moreover, this paper presents the
application of Taguchi method and analysis of variance (ANOVA) for minimization of delamination
influenced by drilling parameters and drill point angle. The optimum drilling parameter combination
was obtained by using the analysis of signal-to-noise ratio. The conclusion revealed that feed rate and
cutting speed were the most influential factor on the delamination, respectively. The best results of the
delamination were obtained at lower cutting speeds and feed rates.

Keywords:
Taguchi method Analysis of variance, Design optimization, Drilling ,Delamination ,Glass fibre
reinforced plastic composites

Conclusions
This paper has presented an application of the Taguchi method for investigating the effects of cutting
parameters and point angles on the delamination factor in dry drilling of GFRP composites. The
conclusions of this present study were drawn as follow:
– The analysis of experimental results is carried out using Taguchi’s orthogonal array and analysis of
variance. The level of the best of the cutting parameters and point angles on the damage is determined
by using ANOVA.
– The damage increases with both cutting parameters, which means that the composite damage is bigger
for higher cutting speed and feed rate.
– The results of ANOVA revealed that feed rate is the main cutting parameter, which has greater
influence on the delamination factor for both drills (except point angle of 135_, at exit). Low feed rates
provided minimum damage. The delamination factor at entrance and exit is minimal, both at point angle
of 118_ and 135_.
– The point angle of 118_drill produces less damage on the entrance of GFRP composite than the point
angle of 135_ drill, i.e., the delamination factor is smaller.
– Based on the S/N, optimal parameters for the minimum entrance damage are the cutting speed at Level
1 (5 m/min) and the feed rate at Level 1 (0.1 mm/rev).
– Similarly, the optimum cutting parameters for minimum exit damage are cutting speed at Level 1 (5
m/min) and the feedrate at Level 1 (0.1 mm/rev).
11 K. Palanikumar, J. Statistical Analysis of Delamination in Journal of Composite
Campos Rubio, A. Abrão, Drilling Glass Fiber-Reinforced Materials
A. Esteves and J. Paulo Plastics (GFRP) Vol. 27, No. 15/2008
Davim SAGE PUBLICATION

ABSTRACT:
Fiber-reinforced composites are widely recognized for their superior mechanical properties and
advantages for applications in aerospace, defence and transportation sectors. Delamination is a problem
associated with drilling fiber-reinforced composite materials. In this work, the effects of feed speed,
rotational speed and drill geometry on the resulting delamination factor are comparable in spite of the
drill point angle used. A mathematical model is proposed to predict delamination in drilling glass fiber-
reinforced plastic composites.
KEY WORDS: composite laminates, drilling, delamination factor, modeling.

CONCLUSIONS
. Experiments were conducted to study the influence of the machining parameters on delamination of
laminated composites when drilling. The output response considered for the analysis was delamination
factor Fd. An empirical model has been developed for correlating the drilling parameters to the
delamination factor.
. The experiments conducted and the developed model are suitable techniques to predict the effects of
different drilling parameters and their interactions by conducting a minimum number of experiments.
. The developed model can be used to predict the delamination factor in drilling of GFRP at 95%
confidence level. However, the validity of the model is limited to the range of parameters considered
for the investigation. The accuracy of the developed model can be improved through the inclusion of
additional drilling parameters and levels.
. Feed speed is the factor which has greatest influence on delamination factor, followed by rotational
speed. Drill point angle has limited influence on the delamination factor. The interactions between the
parameters also have some effect on Fd. Among the interactions considered, rotational speed and drill
point angle seem to be the most significant.

12 A.M. Abra˜o , J.C. The effect of cutting tool geometry on Materials and Design
Campos Rubio, P.E. Faria, thrust force and delamination when 29 (2008) 508–513
J.P. Davim drilling glass fibre reinforced plastic ELSEVIER
composite

Abstract
This work is focused on the investigation of the effect of the cutting tool geometry and material on the
thrust force and delamination produced when drilling a glass fibre reinforced epoxy composite. Four
drills with distinct geometries and composition were tested. Additionally, the influence of the cutting
parameters was studied. Generally speaking, the results indicated that lower thrust force was observed
using drill EDP27199, whereas drill A1167A (with three cutting edges) gave highest thrust force values.
In contrast to other reports, a direct relationship between thrust force and delamination was not
observed, i.e., the drill responsible for the highest thrust force was also responsible for the second
smallest delaminated area. Finally, within the cutting range tested the damaged area increased
considerably with feed rate and moderately with cutting speed.

Key words : Drilling, Thrust Force ,GFRP, Cutting tool

Conclusions

After drilling glass fibre reinforced epoxy composite laminates using four different tool materials and
geometries
and various cutting speeds and feed rates, the following conclusions can be drawn:
_ Lower thrust force was recorded using drill EDP27199. Its geometry allows the cutting action to
happen from
the outer to the inner tool diameter, similarly to a trepanning tool.
_ Highest thrust force was recorded when drilling with tool A1167A, which despite possessing three
cutting edges presented a point angle of 150_, shown to be detrimental.
_ Thrust force was elevated as feed rate was increased due to the elevation in the shear area. The
influence of cutting speed on thrust force was negligible. Additionally, tool wear, caused mainly by
abrasion, was the principal wear mechanism and led to the elevation of the thrust force.
_ The drill which promoted the lowest thrust force (drill EDP27199) was responsible for the least
damage on the laminate, nevertheless, the drill responsible for the highest thrust force values (drill
A1167A) accounted for the second smallest delaminated area. This suggests that the relationship
between thrust force and delamination is not straightforward.
_ Finally, within the cutting range tested the damaged area increased considerably with feed rate and
moderately with cutting speed.

13 P.E. Faria, R.F. Campos, Thrust Force and Wear Assessment Journal of Composite
A.M. Abrão, G.C.D. When Drilling Glass Fiber-Reinforced Materials
Godoy and J.P. Davim Polymeric Composite Vol. 42, No. 14/2008
SAGE PUBLICATION
ABSTRACT:

The principal aim of this article is to investigate the influence of the drilling parameters and tool
material/coating (high speed steel and plain and coated carbide) on the thrust force and tool wear when
drilling glass fiber reinforced epoxy composite. In order to predict the performance of the cutting tools
in the industrial environment, extended drilling tests (up to 24 000 holes) were conducted and the
influence of changes in the geometry of the drills on the thrust force was assessed. The results indicated
that the high speed steel tool presented remarkable wear rates, which drastically altered its edge
preparation and resulted in a thrust force of 492N after 1000 holes. In opposition to that, the cemented
carbide drill presented superior wear resistance, with a thrust force of 147N after drilling 24 000 holes.
Finally, the use of the titanium nitride coated drill did not offer a significant contribution neither to the
tool wear resistance nor to the machining thrust force.

KEY WORDS: drilling, composite, thrust force, tool wear.

CONCLUSIONS

The following conclusions can be drawn from this work:

. The ball-on-disc tests showed the superior resistance to adhesive wear of the cemented carbide against
glass fiber reinforced epoxy composite in comparison to the high speed steel with regard to both wear
depth and coefficient of friction.
. After drilling 1000 holes, the thrust force value increased drastically with the A1141 high speed steel
drill reaching 492N at the end of the test, while the maximum thrust force value recorded for the A1163
carbide drill was 92 N.
. The analysis of variance conducted using the thrust force values obtained when drilling the thousandth
hole under distinct cutting conditions indicated that feed rate significantly affects thrust force when
drilling with the cemented carbide drill.
. When drilling 10,000 holes with the uncoated and TiN coated carbide drills, the thrust force values
were not affected by tool coating, presenting a smooth increase with the number of holes produced.
Furthermore, the uncoated carbide drill produced 24,000 holes with a thrust force value below 150 N.
. The analysis of the worn tools suggested that abrasion was a major wear mechanism involved, being
responsible for the deterioration of the cutting edge of the high speed steel after 1000 holes, for the
removal of the TiN film from the coated tool after 10,000 holes and for the reduction in the diameter
and tool tip angle of the uncoated carbide tool after 24,000 holes. Evidence of adhesive wear was not
observed probably owing to the low magnifications used in the SEM analysis.
14 L.M. Durão1a; Daniel J.S. DRILLING DELAMINATION Details Not Available
Gonçalves, João Manuel OUTCOMES ON GLASS AND
R.S. Tavares, SISAL REINFORCED PLASTICS
Victor H.C. de
Albuquerque, Túlio H.
Panzera, Leandro J.Silva,
A.A. Vieira, A. M.
Baptista

Abstract.
Now a days, fibre reinforced plastics are used in a wide variety of applications. Apart from the most
known reinforcement fibres, like glass or carbon, natural fibres can be seen as an economical alternative.
However, some mistrust is yet limiting the use of such materials, being one of the main reasons the
inconsistency normally found in their mechanical properties. It should be noticed that these materials
are more used for their low density than for their high stiffness. In this work, two different types of
reinforced plates were compared: glass reinforced epoxy plate and sisal reinforced epoxy plate. For
material characterization purposes, tensile and flexural tests were carried out. Main properties of both
materials, like elastic modulus, tensile strength or flexural modulus, are presented and compared with
reference values. Afterwards, plates were drilled under two different feed rates: low and high, with two
diverse tools: twist and brad type drill, while cutting speed was kept constant. Thrust forces during
drilling were monitored. Then, delamination area around the hole was assessed by using digital images
that were processed using a computational platform previously developed. Finally, drilled plates were
mechanically tested for bearing and open-hole resistance. Results were compared and correlated with
the measured delamination. Conclusions contribute to the understanding of natural fibres reinforced
plastics as a substitute to glass fibres reinforced plastics, helping on cost reductions without
compromising reliability, as well as the consequence of delamination on mechanical resistance of this
type of composites.

Keywords: glass fibre; sisal fibre; drilling; delamination; image analysis

Summary
A comparison of glass/epoxy and sisal/epoxy plates mechanical performance after drilling was
presented. Experimental work included thrust force monitoring during drilling and measurement of
delamination extension and mechanical testing after drilling. Based on the experimental work and
conditions presented, some conclusions can be drawn:
- maximum thrust force and delamination extension depend on drilling conditions, tool geometry
and material;
- for higher feed rates, thrust force and delamination extension are superior;
- mechanical test results are more dependent of material nature than on drilling conditions;
- sisal/epoxy unidirectional plates are not well suited for screw or bolt connections;
- the result needs to be further confirmed by testing cross-ply or mat sisal/epoxy plates.
15 B. Latha & V. S. Analysis of Thrust Force in Drilling Materials and Manufacturing
Senthilkumar Glass Fiber- Reinforced Plastic Processes
Composites Using Fuzzy Logic 24: 509–516, 2009

Abstract:
Glass fiber-reinforced plastic (GFRP) composite materials are finding increased application in many
engineering fields. Machining of these materials cannot be avoided to get accuracy and precision fits.
Among the various machining processes used, drilling is one of the most important processes and is
mainly used in joining of composite structures. A major problem which encountered in drilling of GFRP
composite laminate is damage or delamination. The damage due to thrust force is the important concern
in drilling, and it leads to poor machinability. In the present work, prediction of thrust force in drilling
of composite materials is carried out using fuzzy logic. Fuzzy rule-based model is developed to predict
the thrust force in drilling of GFRP composites. The effectiveness of the fuzzy model was compared
with the response surface model. Good agreement is observed between the predictive model values and
experimental values. The analysis of machining parameters on drilling is carried out using Pareto
analysis of variance (Pareto–ANOVA) and analysis of variance (ANOVA).

Keywords
Analysis of variance (ANOVA); Brad and spur drill; Composites; Delamination; Drilling; Drilling
parameters; Fuzzy logic; Glass fiber-reinforced plastics (GFRP); Membership function; Modeling;
Pareto ANOVA; Polymer matrix; Response surface method; Rule base; Thrust force,RSM.

Conclusions
Experiments are conducted for analyzing thrust force in drilling of GFRP composites. The machining
parameters considered for the experiments are spindle speed, feed rate, and drill diameter. From the
analysis, the following conclusions were drawn:
1. Rule-based fuzzy logic model for thrust force is developed from the experimental data. The predicted
fuzzy output values and measured values are fairly close to each other, which indicate that the fuzzy
logic model can be effectively used to predict the thrust force in drilling of GFRP composites.
2. The effect of different parameters on drilling of GFRP composites is analyzed through Pareto
ANOVA and classical ANOVA.
3. The results revealed that feed rate and drill diameter are the factors that influence the thrust force in
drilling of GFRP composites. Spindle speed shows only very limited effect on thrust force. The
interaction between spindle speed and feed rate also shows some effect in the drilling of composite
materials.
4. Response surface model is also developed to judge the effectiveness of correlation between the
parameters.
5. Verification results reveal that the fuzzy rule-based model is better than the response surface model
for predicting the thrust force in drilling of GFRP composites.
6. The optimal condition found in this work is only near optimal. For finding the very real optimum
conditions, further investigations are required.
7. The utilization of this system can improve the quality of the drilled part, and it paves the way for
online condition monitoring.
16 S. Arul, D. Samuel Modeling and Optimization of Materials and Manufacturing
Raj , L. Process Parameters for Processes
Vijayaraghavan, S. K. Defect Toleranced Drilling of GFRP 21: 357–365, 2006
Malhotra & R. Composites
Krishnamurthy

Drilling is a frequently practiced machining process for fiber-reinforced plastics (FRP) in industry
owing to the need for component assembly in mechanical structures. Drilling experiments are performed
on a _0/±45/90_2s 3-mm-thick glass fiber-reinforced laminate using 4-, 6- and 8-mmdiameter HSS
drills. The machining response of the quasi-isotropic laminate was studied by monitoring the thrust and
torque. The performance of the HSS drills for different cutting conditions was studied by measuring the
tool wear. Delamination due to drilling is a major concern in machining a composite laminate and is
analyzed by using linear elastic fracture mechanics, classical plate bending theory, and the mechanics
of composites. A mechanical model for evaluating the critical thrust at which delamination is initiated
at different ply locations has been used, and the critical thrust force at the onset of delamination has
been found to be 70 N. The present work analyzes data on the thrust force, torque, and tool life by using
a group method data handling (GMDH) algorithm. An optimization algorithm using simulated
annealing with a performance index is then applied to search for the optimal process parameters for
delaminatien constrained drilling.

Keywords Delamination; Drilling; FRP; GMDH algorithm; Simulated annealing.

Conclusions
The critical thrust force at the onset of delamination was 70N with use of the analytical model developed
by Zhang et al., which is in good agreement with the experimental results because the material response
deteriorates by way of rapid increase in thrust component beyond 70 N. The GMDH algorithm can be
used to model stochastic processes such as drilling of composites, which is a complex process depending
on many factors. The maximum tool life is obtained when the drilling is done at the following
conditions: cutting speed = 18_85m/min and feed rate = 0_02mm/rev.
17 PK Rakesh, I Singh Drilling of composite laminates with Journal of Composite
and D Kumar solid and hollow drill point Materials
geometries 46(25) 3173–3180

Abstract
Drilling is one of the most important method for hole making in composite materials. Drilling of
polymer matrix composites causes substantial damage around the drilled hole. Damage free holes can
be made using modified drill geometry. The present research investigation focuses on the drill geometry
as candidate parameter that influence drilling forces and drilling-induced damage. The four different
drill geometries (solid and hollow in shape) are used for drilling in composite materials. The cutting
mechanism of these drill geometries is substantially different, and therefore influences the drilling-
induced damage. The experimental results suggest a strong relationship between the drill point geometry
and the drilling-induced damage.

Keywords
Drill geometry, drilling, glass fiber reinforced plastic, drilling forces,RSM,ANOVA
Conclusion
The primary objective of the present research initiative was to experimentally investigate the effect of
drill point geometry on the drilling forces and subsequently on the drilling-induced damage in GFRP
laminates. The cutting mechanisms of the different drill point geometries were analyzed. The following
conclusions can be drawn from the present research endeavor:
1. The cutting mechanism of the drill point geometries under investigation is substantially different and
it affects the drilling forces and subsequently the drilling- induced damage.
2. The cutting mechanism of hollow drills is especially suitable for drilling in laminated composites. In
Trepanning tool and U shape drill, the cutting starts from the outer periphery of the tool which places
the fibers under tension during the entire cutting operation leading to lower magnitudes of forces
and the drilling-induced damage.
3. The thrust force generated with the Twist drill was 2.5 times higher than the U shape drill, therefore
the Twist drill is not recommended for the drilling of GFRP laminates.
4. The drilling forces recorded with the hollow drills (U shape and Trepanning tool) were lower than
the forces recorded with the solid drills (Twist and Jo drill).
5. The minimum drilling forces and the minimum delamination factor were found with the U shape
drill.
6. The drill point geometry has a substantial effect on the drilling forces and the drilling-induced
damage.
7. In future, intra-drill analysis (focussing on the hollow drills) can be attempted for optimizing the
various tool angles of the hollow drills for specific composite materials such as carbon fiber reinforced
plastics or kevlar fiber reinforced plastics.