TECHNICAL ARTICLE

Measuring Delamination Severity of Glass Fiber-Reinforced Epoxy Composites During Drilling Process
V.A. Nagarajan1 , S. Sundaram2 , K. Thyagarajan3 , J. Selwin Rajadurai4 , and T.P.D. Rajan5
1 Faculty of Mechanical Engineering, Anna University, Tirunelveli, Nagercoil, India 2 Department of Manufacturing Engineering, Annamalai University, Chidambaram, India 3 Department of Mechanical Engineering, Noorul Islam College of Engineering, Kumarcoil, India 4 Department of Mechanical Engineering, Government College of Engineering, Tirunelveli, India 5 National Institute for Interdisciplinary Science and Technology, CSIR, Trivandrum, India

Keywords Drilling, Delamination Severity, MATLAB, Glass Fiber Epoxy Composites Correspondence J. Selwin Rajadurai, Department of Mechanical Engineering, Government College of Engineering, Tirunelveli, Tamilnadu, India Email: j_selwinrajadurai@yahoo.co.in Received: June 27, 2011; accepted: December 3, 2011 doi:10.1111/j.1747-1567.2012.00809.x

Abstract
Glass ber-reinforced epoxy composites are one of the potential lightweight structural materials used in various engineering applications due to its excellent properties. Drilling is most widely applied for fastening the composite structures; nevertheless, the damage induced by this operation may reduce the component performance drastically. To establish the damage level, delamination is measured quantitatively using digital imaging techniques. In this study, to quantify the delamination severity effectively, a new rened delamination factor (FDR ) is proposed and validated using experimental results observed from three-point bend tests (3PT) and modied short beam shear tests. The value of determined rened delamination factor (FDR ) is more accurate compared to the calculated conventional (FD ) and adjusted (FDA ) delamination factors.

Introduction Application of composite materials is dominating in engineering eld due to good specic strength, stiffness, fatigue limit, light weight, and near net shape production technique available for the processing, molding, and curing of ber-reinforced plastics (FRP) to achieve the desired tolerances.1 One of the main difculties associated with drilling of composite material is delamination failure. According to Khashaba,2 delamination is one of the main reasons for the rejection of approximately 60% of the composite components produced in aircraft industries. When the stresses induced in the layers of the laminate during the drilling operation exceed the interlaminar strength of the laminate, delamination failure occurs. The inuence of factors such as tool geometry and machining parameters on delamination has been studied by several researchers. Nevertheless, few authors have approached both tool geometry and high-speed machining (HSM) when drilling composites, more specically glass ber composites.
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Even though many researchers have attempted on the effect of tool geometry and machining parameters on delamination, only very few have focused on the same with drilling of composite laminates. Inuence of different drill geometry on delamination of laminates fabricated through hand lay-up technique was investigated by Davim et al.3 The author employed a toolmakers microscope to evaluate the damage. In that study, the inuence of vibration frequency and amplitude during drilling of composites was considered. Arul et al.4 express that the delamination factor as the ratio of maximum diameter in the damaged zone to the drill diameter. The results indicated that the damage increases with increase in both cutting speed and feed rate. Next, the authors employed an optical microscope coupled with an image analyzer to study the extent of defects caused by drilling. In this work, the authors characterize delamination factor as a ratio of the maximum diameters in the damaged zone to the drill diameter. After drilling holes of small diameters,
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Aoyama et al.5 concluded that the delamination is generated along the ber in the hole wall surface and it propagates as the surface roughness increases. Apart from the above, few more works were carried out in the eld of HSM, and attempts were made to obtain relationship between various controllable parameters and their inuence on quality of drilled hole. Kao et al.6 investigated the tribological properties of coated drills against the holes drilled on glass ber-reinforced epoxy resin laminates. From the results, the authors concluded that drills coated with 5% MoS2 Cr have increased the life of the drill bits, two times than that of uncoated drills. The inuence of tool point angle, spindle speed, and feed with respect to delamination was discussed, and the delamination was also measured digitally in the study of Compos Rubio et al.7 From the discussion mentioned above, delamination and surface nish are the two important variables that need focus during drilling of composite laminates. These two variables are inuenced by other process parameters such as feed rate, cutting speed, drill geometry, tool wear, and tool material.8 12 The delamination failure in drilling operation can occur either at drill bit entry, known as peel-up, or at the exit of the bit, termed as push-out. Out of these two delamination mechanisms associated with drilling of FRP, push-out at the drill exit is more severe. The key for solving the problem lies in reducing the thrust force when drilling. Optical microscopy and scanning and digital photography are the techniques employed to measure the delamination qualitatively. The same can be measured quantitatively as follows. Delamination factor is one such parameter, which is used to characterize the level of damage on the work material at the entry and exit of the drill. The delamination factor (FD ) may be calculated from the ratio of the maximum diameter (Dmax ) of the delamination zone to the drill diameter (D0 ) as follows:13 FD = Dmax D0 (1)

(Dmax ), and A0 is the area of the nominal hole, which corresponds to D0 . Even though the delamination is estimated quantitatively by various researchers using either delamination factor or adjusted delamination factor, in this work it was observed that the specimen with lower adjusted delamination factor gets failed more quickly than the do specimens with higher adjusted delamination factor. This insists the need for a revision in the current form of adjusted delamination factor. Hence in the revised form of delamination factor equation, in addition to damage zone size, drill diameter and area correspond to nominal diameter; importance was given to severity of damages. Experimental Procedure Drilling experiments were conducted on a CNC machining center with 5-kW power. Its spindle speed range is 2002500 rpm with a resolution of 1 rpm, and the feed range is from 5 to 200 mm/min. The laminates were produced by the hand lay-up technique and were made up of epoxy matrix reinforced with 62% weight of woven glass ber with an orientation of ve layers of [0/45 ] and two layers of [0/90 ] laminates. Fourteen layers of glass ber were used resulting in a 9.57-mm-thick laminate. Table 1 shows the mechanical properties of composite material used for testing.14 The sized composite laminate of 160 80 mm was xed on the machining center using appropriate clamping device and back plate. Then the laminate was drilled using a brand new 10-mm end mill cutter made up of high-speed steel, and the detail is shown in Fig. 1. Drilling was performed by varying spindle speeds and feeds. A feed rate of 25150 mm/min in steps of 25 mm/min was used in the experimental work. The same set of feed rates was used for spindle speeds of 1000, 1200, and 1400 rpm. Eighteen holes were drilled for the specied cutting parameters for a single cutting tool of an individual size. In order to account for unforced errors and damages induced during machining operation, three holes of same parameter were drilled, so the
Table 1 Mechanical properties of composite material used for testing Fiber type Matrix type Fiber volume fraction, Vf Longitudinal modulus, E11 (GPa) Transverse modulus, E22 (GPa) In-plane shear modulus, G12 (GPa) Major Poissons ratio, 12 E-glass 21xK43 Gevetex LY556/DY063 epoxy 0.62 34.41 6.53 3.43 0.217

Alternatively, the ratio of the delaminated area to the hole area may also be used. In this case, the adjusted delamination factor (FDA ) is calculated from Eq. 2, in which the rst part represents the size of the crack contribution (conventional delamination factor FD ) and the second part represents the damaged area contribution. FDA = FD + AD (F 2 FD ) (Amax A0 ) D (2)

where AD is the damaged area, Amax is the area related to the maximum diameter of the delamination zone
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(a)
Computer Digital Camera

(b)
Series of Lights Camera Stand

(c)
Laminate Specimen

Figure 2 Line sketch for the camera setup.

Figure 1 Various types of drilling cutters of 10 mm diameter, (a) router, (b) end mill cutter, and (c) twist drill.

total number of holes required was worked out to be 54. Results and Discussion The damage at the push-out was captured qualitatively using a Nikon 300 digital camera (Nikon India Private Ltd., India) with ST 800 ash. The lighting environment must be adequate enough to obtain a good response out of the sensor, but not too excessive to cause blooming or saturation of the sensor. Series of ber-optic point sources lighting were used to minimize the effects of ambient lighting and simplify image processing. The line sketch for the camera setup is shown in Fig. 2. The size of the damage zone was measured quantitatively5,15 18 using the concept of neural network MATLAB 7.0 software. Using Eqs. 1 and 2, delamination factor (FD ) and adjusted delamination factor (FDA ) proposed by various researchers are calculated and shown in Table 2. On the other hand, the drilled specimens were tested by the following tests to conrm and validate the values of FD and FDA . American Society for Testing and Materials (ASTM) has proposed two test standards: (1) three-point bend test (3PT) (D2344) involves the use of a three-point exure specimen to measure interlaminar shear stress of laminated composites subjected to transverse loads19 and (2) the modied short beam shear (MSBS) test (ASTM D790) is also used to estimate the interlaminar shear stress but in MSBS test, in between loading head and specimen one rubber sheer and one stiffer plate aluminum are placed. Main purpose is to make the point
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load as uniformly distributed load. Here, specimen was subjected to uniformly distributed load. That is why the specimen fails in small amplitude of load compared with 3PT. Both the tests offer failure load of the specimen in kilonewtons. Using this failure load, the interlaminar shear stress can be computed using the following equation: xzmax = 3pmax 4bD (3)

where, xzmax refers to maximum induced shear stress in xz plane, in which x refers to the axial direction of the beam and z refers to the thickness direction with the origin coincident with the midthickness plane; pmax is the failure load; b is the width of the specimen; and D is the thickness of the specimen. The results of both of these tests and the computed interlaminar shear stress are given in Table 3. From the above validation tests, the following observations have been made:
Average failure load estimated using 3PT for holes

drilled at 1000 rpm with a 25 mm/min feed rate is 298.21 kN. Corresponding interlaminar shear stress is 353.14 MPa. Average failure load estimated using MSBS test is 242.39 kN and corresponding interlaminar shear stress is 294.27 MPa. Average failure load estimated using 3PT for holes drilled at 1000 rpm with a 150 mm/min feed rate is 372.40 kN. Corresponding interlaminar shear stress is 452.17 MPa.

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Table 2 Calculated delamination factor and adjusted delamination factor for holes drilled with 10-mm end mill for different conditions Maximum length of damage, Dmax (mm) 13.50 15.43 15.08 13.81 12.62 13.92 13.58 16.66 13.75 14.22 12.62 13.87 14.16 12.61 14.12 13.00 14.07 13.59 Total damaged area, AD (mm2 ) 62.22 80.50 93.69 42.47 25.82 69.36 44.40 53.95 51.59 34.62 40.67 101.96 62.34 59.63 37.81 52.34 49.18 91.05 Maximum damaged area, Amax (mm2 ) 143.07 186.90 178.51 149.71 125.02 152.11 144.77 217.88 148.41 158.73 125.02 151.02 157.40 124.82 156.51 132.67 155.40 144.98

Speed (rpm) 1000

Feed (mm/min) 25 50 75 100 125 150 25 50 75 100 125 150 25 50 75 100 125 150

FD 1.350 1.543 1.508 1.381 1.262 1.392 1.358 1.666 1.375 1.422 1.262 1.387 1.416 1.261 1.412 1.300 1.407 1.359

FDA 1.804 2.166 2.226 1.688 1.446 1.907 1.684 2.096 1.756 1.681 1.551 2.140 1.882 1.685 1.694 1.677 1.773 2.027

1200

1400

Table 3 Failure load and interlaminar shear stress by 3PT and MSBS tests, for holes drilled with 10-mm end mill for different conditions Interlaminar Failure shear stress (MPa) load (kN) 298.42 299.67 296.56 298.21 373.07 371.65 372.48 372.40 242.49 243.57 241.11 242.39 309.41 307.84 308.45 308.56 352.54 354.89 351.99 353.14 452.61 453.78 450.12 452.17 294.19 295.95 292.67 294.27 375.38 373.69 374.92 374.66

Test Three-point bend test (3PT)

Parameters 1000 rpm and 25-mm feed

Trail 1 2 3 Average 1 2 3 Average 1 2 3 Average 1 2 3 Average

1000 rpm and 150-mm feed

Modied short beam shear (MSBS) test

1000 rpm and 25-mm feed

1000 rpm and 150-mm feed

Average failure load estimated using MSBS test

is 308.56 kN and the corresponding interlaminar shear stress is 374.66 MPa. Holes drilled with a 25 mm/min feed rate is more prone to failure than that with a 150 mm/min feed rate. The test values obtained by 3PT and MSBS tests are not correlated with the values of FD and FDA obtained through the MATLAB 7.0, so it is in need to make ne tuning in the process of image, and that has been done
Experimental Techniques 37 (2013) 6673 2012, Society for Experimental Mechanics

by the following method. It is a seven-stage process out of which three stages are shown in Fig. 3. Here the importance is given for the depth of damage, which is called as severity of damage. Depending upon the depth of damage or severity of damage, the intensity of reected light from the damaged zone is varied. This image is captured by the digital camera and a set of images are taken for training. During training, the back ground is eliminated by ground truth technique and certain features like primary color components of the image under study are extracted and selected. At the time of testing, the same features are tested with the trained neural network, the mean square error (MSE) is calculated, and the training is carried out till the iteration process reaches the iteration maximum. Finally, the results classied as heavy damaged, medium damaged, and light damaged areas are obtained. These three zones are colored as follows: (1) heavily damaged area (red), (2) medium damaged area (green), and (3) lightly damaged area (light red). The ow chart of the proposed algorithm is represented in Fig. 4. Existing delamination factor or adjusted delamination factor depends on either maximum length of damage (Dmax ) or maximum damaged area (Amax ) and the area of damaged zone (AD ), respectively. Various researchers calculate the value of maximum damaged area (Amax ) by considering only the maximum diameter of the delamination zone (Dmax ). It can be observed from Table 4 that the total area of damage (AD ) for hole drilled with 25 mm/min feed rate and 1000 rpm is 62.22 mm2 , whereas the total area of
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(a) Captured Image

(b) Segregation of pixels depends on its intensity Green: Medium damaged area

(c) Final image for measuring of data Red: Heavily damaged area.
Figure 3 Steps in neural network in MATLAB for the calculation of Dmax and area of damage.

Light Red: Lightly damaged area

Figure 4 Flowchart of the proposed algorithm.

damage (AD ) for hole drilled with 150 mm/min feed rate and for the same speed is 69.36 mm2 only. The magnitude of FDA for the hole mentioned in rst case is 1.804 and for the later is only 1.907. On the basis of the concept proposed in the literature, it can be decided that the hole considered in the second case having FDA value of 1.907 is more prone to damage when compared with the rst case, which has FDA value of 1.804. It means that the damages are high in the second case when compared with the rst case. Hence the measurement of total area of damage (Amax ), which is mainly concentrated around the vicinity of drilled hole alone, is not sufcient to quantify the delamination factor. Because the validation
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tests prove that the holes drilled with a 25 mm/min feed rate is more prone to failure than that of holes drilled with a 150 mm/min feed rate at 1000 rpm. Hence it is very essential to rene the formula in Eq. 2 for the calculation of adjusted delamination factor to correlate with the test values. This process of rening should include the effect of severity of damage. To rene the adjusted delamination factor (FDA ), in addition to the variables Dmax and Amax , the severity of damage should also be accounted for. From Table 4, it can be observed that the heavily damaged area (AH ) for hole drilled with a 25 mm/min feed rate at 1000 rpm is 13.03 mm2 , whereas it is only 4.92 mm2 for the hole drilled with a 150 mm/min feed rate at the same speed. Hence in the formulation of rened delamination factor importance should be given for the severity of damage in addition to the maximum length of damage, total damaged area, and size of the hole. Keeping these points in mind, it is proposed that the delamination failure can be effectively characterized using Buckinghams theorem.20 The Buckinghams theorem states if there are n variables in a physical phenomenon and if these variables contain m fundamental dimensions, then the variables are arranged into (n m) dimensionless terms. Each term is called term. Accordingly, as discussed earlier, in the expression for delamination factor, due importance should be given to severity of damage in addition to Dmax and D0 . Here, the terms (Dmax /D0 ) (AH /A0 ), (AM /A0 ), and (AL /A0 ) were identied as dimensionless terms. The procedure for the development of the proposed rened delamination factor FDR can be summarized as follows: FDR = f (Dmax , D0 , A0 , AH , AM , AL ). This equation can also be expressed in terms of terms as f (1 , 2 , 3 ) = 0.
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Table 4 Split value of damaged area depends on severity for holes drilled with 10-mm end mill for different conditions and its FDR values Feed (mm/min) 25 50 75 100 125 150 25 50 75 100 125 150 25 50 75 100 125 150 Maximum length of damage, Dmax (mm) 13.50 15.43 15.08 13.81 12.62 13.92 13.58 16.66 13.75 14.22 12.62 13.87 14.16 12.61 14.12 13.00 14.07 13.59 Total damaged area, AD (mm2 ) 62.22 80.50 93.69 42.47 25.82 69.36 44.40 53.95 51.59 34.62 40.67 101.96 62.34 59.63 37.81 52.34 49.18 91.05 Heavily damaged area, AH (mm2 ) 13.03 9.37 7.06 6.30 2.44 4.92 3.70 13.02 6.73 4.04 2.31 6.91 7.81 3.91 4.14 2.81 4.66 5.50 Medium damaged area, AM (mm2 ) 23.02 36.96 34.68 10.75 8.02 35.34 12.98 22.20 22.20 12.66 12.06 57.29 20.99 23.04 12.29 16.72 12.01 36.36 Lightly damaged area, AL (mm2 ) 26.17 34.17 51.95 25.42 15.36 29.10 27.72 18.73 22.66 17.92 26.30 37.76 33.54 32.68 21.38 32.81 32.51 49.19

Speed (rpm) 1000

FDR 1.709 1.917 1.818 1.539 1.325 1.650 1.463 2.019 1.586 1.533 1.333 1.929 1.647 1.414 1.524 1.399 1.532 1.646

1200

1400

The terms are expressed as 1 = AH Dmax .X D0 A0

a1

.Y

AM A0

b1

.Z

AL A0

c1

Similarly, 2 = and 3 = Dmax AH .X D0 A0

a3

Dmax AH .X D0 A0

a2

.Y

AM A0
b3

b2

.Z

AL A0
c3

c2

.Y

AM A0

.Z

AL A0

.
Twist Drill End Mill Router

Solving the above and the rened delamination factor FDR can be expressed as FDR = Dmax AH + 1.783 D0 A0 + 0.03692 AL A0
3

Figure 5 Photographic view of drilled holes with 10 mm in size.

+ 0.7156

AM A0

(4)

Calculated values of FDR for the holes drilled by 10-mm end mill with required variables for the calculation are shown in Table 4. To validate the rened delamination factor, additionally, six laminate specimens were drilled using brand new high-speed steel tools namely, twist drill and router (shown in Fig. 1) with 10 mm each by the tools at the spindle speeds of 1000, 1200, and 1400 rpm with the feed rates of 25, 50, 75, 100, 125, and 150 mm/min, with three trails, that is, 108 holes were drilled and one set of drilled specimen is shown in Fig. 5 and the calculated FD , FDA , and FDR values
Experimental Techniques 37 (2013) 6673 2012, Society for Experimental Mechanics

are shown in Table 5, which are scattered due to anisotropic nature of composite materials. The capability of the rened delamination factor to predict the interlaminar failure is validated for these holes with reference to the experimental values. Conclusions In this study, it was found that delamination is a main cause of failure in laminated composite material during drilling. It was evident from the earlier discussion that rened delamination factor (FDR ) quanties the delamination failure very effectively when compared with the conventional (FD ) and adjusted (FDA ) delamination factors, which were explained in the literature. This is because of the fact
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Table 5 Calculated FD , FDA and their FDR values for holes drilled with 10-mm twist drill and router for different conditions Twist drill Speed (rpm) 1000 Feed (mm/min) 25 50 75 100 125 150 25 50 75 100 125 150 25 50 75 100 125 150 FD 1.110 1.199 1.288 1.377 1.465 1.554 1.199 1.212 1.376 1.465 1.554 1.642 1.287 1.376 1.465 1.554 1.642 1.631 FDA 1.455 1.494 1.533 1.572 1.610 1.789 1.590 1.601 1.668 1.707 1.746 1.784 1.725 1.764 1.803 1.877 1.881 1.920 FDR 1.250 1.219 1.187 1.155 1.123 1.145 1.456 1.391 1.393 1.361 1.288 1.297 1.566 1.568 1.578 1.567 1.499 1.503 FD 1.252 1.313 1.374 1.436 1.497 1.558 1.248 1.277 1.370 1.431 1.493 1.554 1.244 1.305 1.366 1.427 1.488 1.449 Router FDA 1.623 1.692 1.762 1.831 1.901 1.970 1.658 1.698 1.797 1.867 1.936 2.006 1.694 1.764 1.833 1.902 1.972 1.921 FDR 1.397 1.461 1.526 1.591 1.655 1.720 1.423 1.487 1.552 1.617 1.681 1.746 1.449 1.513 1.578 1.643 1.707 1.672

1200

1400

that the rened delamination factor (FDR ) accounts for the severity of damage. The exactness of FDR is validated with the help of standard test methods for delamination failure proposed in ASTM D2344 and ASTM D790. References
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Notations and Constants

xzmax A0 AD AH AM Amax AL D D0 Dmax FD FDA FDR B pmax Interlaminar shear stress Nominal hole area Damage area Heavily damaged area Medium damaged area Maximum damaged area Lightly damaged area Thickness of the specimen Drill diameter Maximum diameter Delamination factor Adjusted delamination factor Rened delamination factor Width of the specimen Maximum failure load

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