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Materials and Manufacturing Processes

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Damage Investigation in Drilling of Glass Fiber Reinforced Plastic Composite Laminates

Dr. N. Bhatnagar , I. Singh & D. Nayak
a a a a

Department of Mechanical Engineering, Indian Institute of Technology, Delhi, India

Available online: 07 Feb 2007

To cite this article: Dr. N. Bhatnagar, I. Singh & D. Nayak (2004): Damage Investigation in Drilling of Glass Fiber Reinforced Plastic Composite Laminates, Materials and Manufacturing Processes, 19:6, 995-1007 To link to this article: http://dx.doi.org/10.1081/AMP-200034486

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MATERIALS AND MANUFACTURING PROCESSES Vol. 19, No. 6, pp. 9951007, 2004

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Damage Investigation in Drilling of Glass Fiber Reinforced Plastic Composite Laminates

N. Bhatnagar,* I. Singh, and D. Nayak
Department of Mechanical Engineering, Indian Institute of Technology, Delhi, India

ABSTRACT
Machining of fiber reinforced plastic is a process that is substantially different from metals. The inherent anisotropy in the material system makes the material removal mechanism quite complex. Drilling composite materials is necessary to ascertain the structural integrity of intricate composite products. Drilling of laminated structures results in extensive damage around the drilled hole. This study is an attempt to quantify and propose mathematical models for drillinginduced damage in terms of the cutting speed and the feed speed. Mathematical models have also been proposed for the resulting thrust force and the torque. Four different drill point geometries, namely 4-faceted, 8-faceted, parabolic, and Jodrill, are investigated in this study. Key Words: Drilling; GFRP; Damage; Drill geometry; NDT.

*Correspondence: Dr. Naresh Bhatnagar, Department of Mechanical Engineering, Indian Institute of Technology, Delhi 110016, India; Fax: 91-11-26582053; E-mail: nareshb@mech.iitd.ernet.in. 995
DOI: 10.1081/LMMP-200034486 Copyright & 2004 by Marcel Dekker, Inc. 1042-6914 (Print); 1532-2475 (Online) www.dekker.com

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INTRODUCTION Unlike most engineering materials, polymeric composites are characterized by marked anisotropy, structural inhomogenity and lack of plastic deformation behavior. Near-net shape manufacturing capabilities of fiber reinforced plastic (FRP) along with their high specific strength and stiffness make them attractive in almost all fields of engineering, ranging from aerospace to consumer goods. Additional benefits in the form of corrosion resistance, lower maintenance costs, ease of transportation, and installation make them very useful material. Although most of the composite products are made to a near-net shape, subsequent machining is required for assembly purposes. Drilling is one of the most important, frequently practiced, and unavoidable machining operation for components used in FRP composite structures. Intricacy in structures necessitates hole generation to facilitate assembly. The mechanism of drilling composite materials has been recognized as a process fundamentally different from that of homogenous metal removal. The diverse properties of the fiber and the matrix combined with fiber orientation have a significant effect on the drilling process. During drilling, the fibers take a high proportion of the load, which prevents uniform plastic deformation as normally observed during chip formation in metal cutting. Composite materials pose additional difficulties while solving the problem of controlling the drilling process. These difficulties arise from the anisotropic nature of the material, as determined by the stacking sequence of the laminate. This prevents the use of empirical models for control due to the difficulty in dealing with the large number of parameters that determine the material characteristics and quantifying them with any certainty. Drilling-induced damage is one of the important factors that influence the long-term performance deterioration of the composite product. The estimation and characterization of drilling-induced damage therefore becomes imperative for ascertaining the reliability and durability of composite structures with drilled holes. A number of attempts correlating the damage zone to the drilling parametersthat is, cutting speed and the feed ratehave been made. Tagliaferri et al.[1] correlated the damage zone width to the ratio of cutting speed and feed rate. It was found that the higher the ratio, the better the cut quality. Chen[2] proposed a statistical model correlating the delamination factor with the average thrust force. Theoretical models by Lachaud et al.[3] and Zhang et al.[4] have been developed that predict the critical thrust force beyond which delamination (damage at the exit side of the hole) takes place. Linear elastic fracture mechanics and the classical plate bending theory principles have been used to develop such models. These models focus on thrust force as the principal factor that causes material damage during drilling. Application of these models to the practical drilling operation requires an in-depth study. Drill point geometry is another important parameter that considerably influences drillinginduced damage. Mathew et al.[5] found that thrust force is considerably lower for trepanning tools in comparison to the standard twist drill. Chen[2] studied the effect of various geometry parameters (point angle, helix angle, web thickness) and correlated them to the cutting forces. Miller[6] carried out a study on various drill point geometries, but the damage estimation was purely qualitative in nature. This research initiative is an attempt to quantify drilling-induced damage (delamination), and to correlate it with the drilling parameters and the cutting forces.

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EXPERIMENTAL SETUP Drilling of FRP composite laminates depends on the cutting speed and the feed rate, along with tool geometry and other material parameters. In this study, these are recognized as the prime factors that influence drilling-induced damage. Four-layered [(0/90)/0]s glass fiber reinforced plastic (GFRP) laminates were made by a hand layup technique. Curing was done at room temperature for about 24 h. The matrix was epoxy with a standard grade of LY556 with hardener HY951. The fiber volume fraction was calculated using the ignition loss method (ASTM D2584-68) and was found to be 0.60 on an average of five samples. The specimens were cut to size of 100 50 mm and 4 mm thickness. As shown in Fig. 1, a CNC machine was used to drill holes in laminates. The specimens were mounted on top of a drill dynamometer (Kistler, Type 9272); the thrust force and torque signals from the dynamometer were routed to the charge meters and were recorded in the IBM PC via A/D card. Solid carbide drills (K-10) of diameter 4 mm and 8 mm were used in the experiments. The type of drill point geometry was one of the important factors of investigation in the experiments. Four types of solid carbide drills namely 4-faceted, 8-faceted, parabolic point, and Jodrill were used. All the drills selected were of substantial different geometries and were expected to behave differently under similar drilling conditions. Different drill point geometries are shown in Fig. 2.

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Figure 1.

Experimental setup.

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(a) Jodrill

(b) 8-faceted

(c) 4-faceted
Figure 2.

(d) Parabolic

Different drill point geometries under investigation.

EXPERIMENTATION The experiments were carried out at different levels of cutting speed and feed rates. As has been reported,[7] carbide drills give better surface finish and more holes to failure; therefore, HSS drills were eliminated from this study. After an initial trial run, a suitable range of cutting speed and feed was chosen for which the visual damage around the drilled hole was minimum. The cutting speed/feed speed (Vs/Vf) was defined as a nondimensional parameter, and the damage quantification was done at different values of Vs/Vf. The nondimensional parameter Vs/Vf was varied from 450 to 2800. The cutting forces, namely torque (T) and thrust (F), were recorded using the drill dynamometer.

Quantification of Drilling-Induced Damage Delamination, matrix burning, fiber pullout, and circularity defects are some of the drilling-induced damage forms. Delamination is one of the most common damage form usually associated with drilling of laminated structures. The last plies tend to open up as the drill pierces through the laminate to generate a hole. A general perception recognizes the thrust force as the main culprit causing delamination. A nondestructive dye penetrant test in conjunction with digital image processing was used to quantify the drilling-induced damage at the exit side of the hole. A fluorescent dye, Zyglo 27-A, with a specified combination of developer was sprayed

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around the drilled hole. The laminates were left to dry for 30 min. The specimens were observed under ultraviolet light. The fluorescent dye penetrated into the damaged zone and gave a clear picture of the drilling-induced damage around the hole. Digital images of the drilled holes after the nondestructive inspection were recorded under ultraviolet light using a digital camera (Sony). Digital image processing was then used to quantify the drilling-induced damage. Image segmentation and thresholding principles that are based on the difference in the gray-scale values of image pixels were used to distinguish the damaged area around the drilled hole.

RESULTS AND DISCUSSION Thrust and Torque Response Figure 3 shows the thrust force signals for different drill point geometries. It is quite evident that the variation in the drill point geometry results in a characteristic variation in the drilling behavior of different drill points. The stepped-drill (Jodrill) gives a characteristic plot showing the variation very clearly. The variation in the signals for a single drill point may be attributed to the heterogeneous nature of the

Figure 3. Thrust force response of different solid carbide drill point geometries with respect to time at cutting speed (Vs)/feed speed (Vf) 2800.

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Figure 4. Torque response of different drill point geometries with respect to time at cutting speed (Vs)/feed speed (Vf) 1800.

composite laminate. The fibers take a higher proportion of the load and thus impair the uniform plastic deformation of the material. The drill point encounters fibers and matrix at regular intervals, and therefore, there is a variation in the signals for a single drill point. Generally, for all the drill points, it can be observed that the thrust force signal increases with time and attains a maximum value at the time of complete engagement of the drill point with the laminate and then decreases as the drilling process is completed. The thrust force signal for the 8-faceted drill point shows a continuous nature, whereas some aberrations are observed with the 4-faceted and the parabolic point. Figure 4 shows the torque response of different drill point geometries. A typical behavior observed with the Jodrill can be attributed to the stepped shoulder that characterizes the drill geometry for Jodrill. The signals for the 4-faceted and 8-faceted drill points show a wider spread with respect to time, whereas the parabolic point gives a typical peak in the torque signal. Thus, it is evident that the drilling characteristics of different drill point geometries are substantially different and can affect the damage induced around the drilled hole as a result of the drilling process. A general perception relates the drilling-induced damage to a critical thrust force beyond which damage takes place. Theoretical models for critical thrust force based on the linear elastic fracture mechanics and classical plate bending theory have been developed. These models serve as a basis for minimization of the drilling-induced damage. In this study, the cutting forces were investigated as a function of a nondimensional parameter cutting speed (Vs)/feed speed (Vf) ratio. Figures 5 and 6

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[(0/90)/0] GFRP, 4 mm diameter 40 35 Thrust force (N) 30 25 20 15 10 5 0 0 1000 2000 3000 Cutting speed/Feed speed
Figure 5. Thrust force vs. Vs/Vf (drill diameter 4 mm).

4-faceted parabolic 8-faceted Jodrill

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[(0/90)/0]s GFRP, 8 mm diameter 70 60 Thrust force (N) 50 40 30 20 10 0 0 2000 4000 6000 Cutting speed/Feed speed
Figure 6. Thrust force vs. Vs/Vf (drill diameter 8 mm).

4-faceted parabolic 8-faceted Jodrill

highlight the variation of the thrust force with Vs/Vf for four different drill point geometries. It is observed from these figures that the thrust force value shows a continuous decrease (for all the drill point geometries) with an increase in Vs/Vf for both drill diameters investigated. It can also be seen that the 4-faceted drill point records the maximum thrust force. The effect is quite predominant for the 8-mm diameter drill. The parabolic point gives a better thrust force response as compared with other drill point geometries.

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14 12 Torque (N-cm) 10 8 6 4 2 0 0 500 1000 1500 2000 2500 3000 Cutting speed/Feed speed 4-faceted parabolic 8-faceted Jodrill

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Figure 7.

Torque vs. Vs/Vf.

Figure 7 shows the variation of torque with the cutting speed/feed speed ratio. Unlike the thrust force that shows a continous decrease with increasing Vs/Vf ; the torque gives local minima in the variation. The decrease in the torque values toward the end can be attributed to the softening of the matrix due to heat build up at higher cutting speed and lower feed speeds. Moreover, low feed speed increases the engagement time of the drill with the laminate resulting in damage due to heat. The thrust and torque response for different drill point geometries was mathematically modeled using multiple linear regression. The thrust force and torque are expressed as a function of the cutting speed (Vs) and the feed speed (Vf). Different statistical models are proposed. 4-Faceted drill point F 75:488 2E 06 Vs =Vf 2 0:0192 Vs =Vf R2 0:9995 3 2 T 19:572 7E 09 Vs =Vf 3E 05Vs =Vf 0:04 Vs =Vf R2 0:9467 8-Faceted drill point R2 0:9919 F 69:66 2E 06 Vs =Vf 2 0:0192 Vs =Vf 3 2 T 21:322 8E 09 Vs =Vf 4E 05 Vs =Vf 0:0481 Vs =Vf R2 0:8474 Parabolic drill point R2 0:9995 F 48:135 9E 07 Vs =Vf 2 0:01 Vs =Vf 3 2 T 19:223 6E 09 Vs =Vf 3E 05 Vs =Vf 0:0394 Vs =Vf R2 0:7432 Jodrill R2 0:8957 F 44:612 4E 07 Vs =Vf 2 0:0061 Vs =Vf 3 2 T 7:963 4E 10 Vs =Vf 4E 06Vs =Vf 0:0061 Vs =Vf R2 0:9463

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Figure 8. Drilling-induced damage: (a) [(0/90)/0]s laminate, (b) UD-GFRP laminate (8 mm diameter 8-faceted solid carbide drill point at Vs/Vf 2800).

The values of the regression coefficients clearly indicate that the mathematical models fit the experimental data closely.

Drilling-Induced Damage: A Qualitative Analysis Figure 8 shows a drilling-induced damage zone around the drilled hole for two different stacking sequences. It is quite clear from the qualitative analysis that the damage zone in unidirectional (UD)-GFRP laminates is elliptical in shape with the major axis of the ellipse approximately being in the direction of the fibers. The damage zone in the case of [(0/90)/0]s laminates is clearly much smaller than that for UD-GFRP laminates, and is spread around the periphery of the drilled hole. The element of directionality in the damage zone thus found in the UD-GFRP laminates is avoided by placing woven fabric layers at the top and at the bottom of the unidirectional laminates.

Drilling-Induced Damage: A Quantitative Analysis The methodology to quantify drilling-induced damage has already been discussed. Figure 9 gives the variation of damage area/hole area (Da/Ha) with Vs/Vf. It is observed that Da/Ha show local minima for values of Vs/Vf, ranging from 750 to 1500. The trends or the variations for different drill point geometries are qualitatively the same, but differ on the quantitative scale. The values for Da/Ha show a constant increase with increasing Vs/Vf after showing local minima for all drill point geometries. The thrust force (Figs. 5 and 6) decreases with increasing Vs/Vf, whereas the torque (Fig. 7) shows an increase with increasing values of Vs/Vf after exhibiting local minima such as the Da/Ha ratio. Theoretical models developed earlier predicted critical thrust force responsible for the damage and ignored the effect of torque completely. The results of this work thus establish and necessitate the study of torque as an important parameter that

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[(0/90)/0]s GFRP 3 2.8 2.6 2.4 2.2 2 1.8 1.6 1.4 1.2 1 0 500 1000 1500 2000 2500 3000 Cutting speed/Feed speed
Figure 9. Variation of damage area (Da)/hole area (Ha) with cutting speed (Vs)/feed speed (Vf) for four different drill point geometries.

Damage area/Hole area

4-faceted parabolic 8-faceted Jodrill

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influences damage around the drilled hole. It is important to conclude that higher cutting speeds result in substantial material damage around the drilled hole.The values for Da/Ha are less for the 8-faceted drill point and the Jodrill. The 4-faceted and the parabolic point result in higher values for Da/Ha and subsequently larger damage zones. It also becomes clear that the drill point geometry has a significant effect on drilling-induced damage. The 8-faceted and Jodrill are thus the best-suited drill point geometries for drilling GFRP laminates. Figure 10 (a and b) gives a comparison of Da/Ha for two different stacking sequences. It is observed that the laminate with woven fabric layers at the top and the bottom results in a smaller damage zone around the drilled hole as compared with the UD-GFRP laminate. It is therefore advantageous to alter the stacking sequence by placing woven laminate or homogenous laminate as the top and bottom plies to minimize the drilling-induced damage in GFRP laminates. Regression modeling was done to propose mathematical models for the drillinginduced damage zone. A number of fits were tried to model the damage zone. Polynomial regression models gave a good fit to the experimental data. Because the different drill point geometries were substantially different with no common feature or attribute, drill point geometry was not considered as a modeling parameter, and geometry-specific models were proposed. Mathematical models for different drill point geometries are: 4-Faceted drill point Da =Ha 2:4714 3E 07 Vs =Vf 2 0:0007 Vs =Vf 8-Faceted drill point Da =Ha 2:93355E10Vs =Vf 3 2E06Vs =Vf 2 0:0031Vs =Vf R2 0:9467 R2 0:9141

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(a)
Damage area/ Hole area 3 2.5 2 1.5 1

Comparison for stacking sequence (4-faceted) UD-GFRP [(0/90)/0]s GFRP 0 1000 2000 3000

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Cutting speed/Feed speed

(b)
Damage area/ Hole area 3 2.5 2 1.5 1

Comparison for stacking sequence (8-faceted) UD-GFRP [(0/90)/0]s GFRP 0 1000 2000 3000

Cutting speed/Feed speed

Figure 10. Comparison for stacking sequence: (a) 4-faceted, (b) 8-faceted drill point.

Parabolic point Da =Ha 2:98294E10 Vs =Vf 3 2E06 Vs =Vf 2 0:0027 Vs =Vf R2 0:9601 Jodrill Da =Ha 2:8308 3E 10 Vs =Vf 3 2E 06 Vs =Vf 2 0:0024 Vs =Vf R2 0:92 The mathematical models directly relate operating variables that are the cutting speed and the feed speed to the induced damage. The operating variables in a drilling process can be used as control variables to minimize the damage around the drilled hole. A model correlating the damage zone to the cutting forces will necessitate installation of expensive instrumentation to first record the forces and then correlate them to the damage zone. Thus, the models proposed here are useful in estimating beforehand the amount of damage that can develop during drilling and thereby help in specifying a quality criterion. For example, a manufacturer for acceptance of laminates with a drilled hole might specify the Da/Ha value of 2 as a quality criterion. The models may also help to optimize the operating variables for minimizing drilling-induced damage.

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CONCLUSION This research endeavor was undertaken to quantify drilling-induced damage and to correlate it with operating variables. Four different drill point geometries were investigated, and the following conclusions are drawn: 1. Higher thrust force values are recorded for a 4-faceted drill point, which is comparable to the standard twist drill geometry, and therefore, it is not recommended for drilling laminated GFRP composite materials. The thrust and the torque response is relatively better for a parabolic point, but the drilling-induced damage shows a maximum value; therefore, it is concluded that there is no direct relation between the cutting forces and the damage for this drill. Contrary to general belief, maximum damage was not found at the conditions where maximum thrust force was recorded. It is therefore concluded that the theoretical models for predicting critical thrust force must be applied with caution and with certain limitations. The torque also plays a significant role in influencing the drilling-induced damage, and models incorporating both the thrust force and the torque should be developed. Drilling-induced damage in the case of [(0/90)/0]s GFRP laminates was spread around the hole, whereas the damage zone in case of UD-GFRP laminates shows an elliptical nature with major axis along the direction of fibers. Drilling-induced damage depends on cutting speed/feed speed ratio resulting in a local minima between 900 and 1500 for different drill point geometries, and this damage area around the drilled hole increases with an increase in cutting speed/feed speed ratio. The drilling-induced damage in case of the 8-faceted drill point and the Jodrill is minimum. A modified geometry incorporating the best features of these two geometries can be developed for drilling GFRP composite laminates, which requires future design and innovation. The drilling-induced damage zone in the case of [(0/90)/0]s GFRP laminates is smaller as compared with UD-GFRP laminates. It is advisable to use woven layers or homogeneous mats at the top and the bottom to ensure a good quality hole with minimum entry and exit damage. Mathematical models for thrust, torque, and drilling-induced damage have been proposed for different drill point geometries. The best-fit models are selected to model the experimental data. The models are domain specific, limiting operating conditions and the workpiece material investigated in this study. A more generic damage criterion incorporating the material property as one of the variables can be developed in the future.

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ACKNOWLEDGMENT The authors are thankful to Ministry of Human Resource and Development (MHRD), Govt. of India, for providing financial assistance to pursue the research under the project Machinability Index for FRP Composite Materials.

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REFERENCES 1. Tagliaferri, V.; Caprino, G.; Diterlizzi, A. Effect of drilling parameters on the finish and mechanical properties of GFRP composites. Int. J. Machine Tool Manuf. 1990, 30 (1), 7784. 2. Chen, W.C. Some experimental investigations in the drilling of carbon fiber reinforced plastic composite laminates. Int. J. Machine Tools Manuf. 1997, 37 (8), 10971108. 3. Lachaud, F.; Piquet, R.; Collombet, F.; Surien, L. Drilling of composite structures. Comp. Struct. 2001, 52, 511516. 4. Zhang, L.-B.; Wang, L.-J.; Liu, X.-Y. A mechanical model for predicting critical thrust forces in drilling composite laminates. Proc. Instn. Mech. Engrs. IMechE 2001, 215 (B), 135146. 5. Mathew, J.; Ramakrishnan, N.; Naik, N.K. Trepanning on uni-directional composites. Composites. Part A 1999, 30, 951959. 6. Miller, J.A. Drilling graphite/epoxy at Lockheed. Am. Machinist Automated Manuf. 1987, October, 7071. 7. Ramulu, M.; Branson, T.; Kim, D. A Study on drilling of composite and titanium stacks. Comp. Struct. 2001, 54, 6777. Received October 1, 2003 Accepted December 18, 2003

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