The path towards delamination-free drilling of composite materials

Journal of Materials Processing Technology

Volumn 167, Issue 2-3, 2005, Pages 251-264

  Hocheng, H ^a   Tsao, C C ^b  

^a NATIONAL TSING HUA UNIVERSITY   (Taiwan)

^b Tahua Institute of Technology   (Taiwan)

Author keywords

Back up; Delamination; Drilling; Non traditional; Pilot hole; Special drill; Thrust force

Indexed keywords

ANISOTROPY; DEFORMATION; DELAMINATION; DRILLING; FORCE MEASUREMENT; STIFFNESS; STRENGTH OF MATERIALS;

BACK-UP; NON-TRADITIONAL; SPECIAL DRILL; THRUST FORCE;

COMPOSITE MATERIALS;

EID: 23844540370     PISSN: 09240136     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.jmatprotec.2005.06.039     Document Type: Article

References (121)

1. S.R. Ravishankar, and C.R.L. Murthy Ultrasonic imaging for evaluation of drill induced delaminations in composite laminates Proceedings of 14th Conference on Non-Destructive Testing Oxford and IBH Publishing 1996 8 13
2. W. Koenig, C. Wulf, P. Grass, and H. Willerscheid Machining of fiber reinforced plastics Ann. CIRP 34 1985 537 548
3. K. Sakuma, Y. Yokoo, and M. Seto Study on drilling of reinforced plastics - relation between tool material and wear behavior Bull. JSME 27 228 1984 1237 1244
4. F. Veniali, V. A.Di Llio, and V. Tagliaferri An experimental study of the drilling of aramid composites ASME J. Energy Res. Technol. 117 1995 271 278
5. W. Koenig, P. Grass, A. Heintze, F. Okcu, and C. Schmitz-Justin Developments in drilling, contouring composites containing Kevlar Prod. Eng. 1984 56 61
6. C.C. Tsao, and W.C. Chen Prediction of the location of delamination in the drilling of composite laminates J. Mater. Process. Technol. 70 1 1997 185 189
7. H. Hocheng, and H. Puw On drilling characteristics of fiber-reinforced thermoset and thermoplastics Int. J. Machine Tools Manuf. 32 4 1992 583 592
8. W.C. Chen Some experimental investigations in the drilling of carbon fiber-reinforced plastic (CFRP) composite laminates Int. J. Machine Tools Manuf. 37 8 1997 1097 1108
9. D.F. Galloway Some experiments on the influence of various factors on drill performance Trans. ASME 79 1957 191 237
10. W.R. Russell, Drill design and drilling conditions for improved efficiency, ASTME Paper No. 397, 62, 1962.
11. S. Jain, and D.C.H. Yang Effects of feed rate and chisel edge on delamination in composite drilling Process. Manuf. Compos. Mater. PED-49/MD-27 1991 37 51
12. J.A. Miller Drilling graphite/epoxy at Lockheed Am. Machine Auto. Manuf. 131 10 1987 70 71
13. B.A. Mackey How to drill precision holes in reinforced plastics in a hurry Plast. Eng. 1980 22 24
14. J. Hickey Drilling graphite composites Mod. Machine Shop 59 1987 84 90
15. M. Ramulu, M. Faridinia, J.L. Garbini, and J.E. Jorgensen Machining of graphite/epoxy composite materials with polycrystalline diamond (PCD) tools ASME J. Eng. Mater. Technol. 133 1991 430 436
16. F. Klocke, and C. Würtz The use of PCD tools for machining fiber reinforced materials Proc. ECCM-8 1998 509 515
17. H. Inoue, and I. Kawaguchi Study on the grinding mechanism of glass fiber reinforced plastics ASME J. Eng. Mater. Technol. 112 1990 341 345
18. A. Koplev, A. Lystrup, and P. Vorm The cutting process, chips and cutting forces in machining CFRP Composite 14 1983 371 376
19. F. Veniali, A. Di Llio, and V. Tagliaferri An experimental study of the drilling of aramid composites ASME J. E. Res. Technol. 117 1995 271 278
20. J.H. Doran, and C.R. Maikish Machining boron composite B.R. Noton Composite Material Engineering Design 1973 ASM 242 250
21. K. Sakuma, Y. Yokoo, and M. Seto Study on drilling of reinforced plastics-relation between tool material and wear behavior Bull. JSME 27 228 1984 1237 1244
22. A. Al-Hamdan Effect of misalignment on the cutting force signature in drilling J. Mater. Process. Technol. 124 2002 83 91
23. C.C. Tsao, and H. Hocheng Effect of eccentricity of twist drill and candle stick drill on delamination in drilling composite materials Int. J. Machine Tools Manuf. 45 2 2005 125 130
24. L. Zackrisson, I. Eriksson, J. Bäcklund, Method and tool for machining a hole in a fiber-reinforced composite material, Swedish Patent No. 500933, 1994.
25. A.C. Okafor, and Birdsong Effect of drilling conditions, drill material and point angle on acoustic emission and hole exit delamination in drilling advanced fiber reinforced composites Proc. SPIE - Inter. Soc. Opt. Eng. 1999 101 104
26. K. Sakuma, and M. Seto Tool wear in cutting glass fiber-reinforced plastics Bull. JSME 24 190 1981 748 755
27. S.C. Lin, and I.K. Chen Drilling carbon fiber-reinforced composite material at high speed Wear 194 1996 156 162
28. E.U. Enemuoh, A.S. El-Gizawy, and A.C. Okafor An approach for development of damage-free drilling of carbon fiber reinforced thermosets Int. J. Machine Tools Manuf. 41 12 2001 1795 1814
29. C. Murphy, G. Byrne, and M.D. Gilchrist The performance of coated tungsten carbide drills when machining carbon fiber-reinforced epoxy composite materials Proc. Inst. Mech. Eng. Part B 216 2 2002 143 152
30. E. Capello Workpiece damping and its effect on delamination damage in drilling thin composite laminates J. Mater. Process. Technol. 148 2 2004 186 195
31. R. Komanduri Machining fiber-reinforced plastics ASME Mech. Eng. 1993 58 64
32. S.M. Wu, and J.M. Shen Mathematical model for multifacet drills ASME J. Eng. Ind. 105 1983 173 182
33. R. Doerr, E. Greene, B. Lyon, S. Taha, Development of Effective Machining and Tooling Techniques for Kevlar Composites, Technical Report, No. AD-A117853, 1982.
34. M.O. Friedrich, R.O. Burant, and M.J. McGinty Cutting tools/drills: part 5 - point styles and applications Manuf. Eng. 83 1979 29 31
35. W.A. Haggerty, H. Ernst, The spiral point drill - self-centering drill point geometry, ASTE Paper No. 101, 58, 1958.
36. S. Fujii, M.F. DeVries, and S.M. Wu An analysis of the chisel edge and the effect of the d-theta relationship on drill point geometry ASME J. Eng. Ind. 93 1971 1093 1105
37. S.L. Ko, J.E. Chang, and G.E. Yang Burr minimizing scheme in drilling J. Mater. Process. Technol. 140 2003 237 242
38. K.Y. Park, J.H. Choi, and D.G. Lee Delamination-free and high efficiency drilling of carbon fiber reinforced plastics J. Compos. Mater. 29 15 1995 1988 2002
39. S. Jain, and D.C.H. Yang Delamination-Free Drilling of Composite Laminates 1992 ASME Mater. Div. Publ. MD, Anaheim, CA, USA pp. 45-59
40. R.S. Xia, and S.M. Mahdavian Experimental studies of step drills and establishment of empirical equations for the drilling process Int. J. Machine Tools Manuf. 45 2 2004 235 240
41. J. Mathew, N. Ramakrishnan, and N.K. Naik Investigations into the effect of geometry of a trepanning tool on thrust and torque during drilling of GFRP composites J. Mater. Process. Technol. 91 1999 1 11
42. J. Mathew, N. Ramakrishnan, and N.K. Naik Trepanning on unidirectional composites: delamination studies Compos. Part A 30 8 1999 951 959
43. R. Piquet, B. Ferret, F. Lachaud, and P. Swider Experimental analysis of drilling damage in thin carbon/epoxy plate using special drills Compos. Part A 31 10 2000 1107 1115
44. H. Hocheng, and C.C. Tsao Comprehensive analysis of delamination in drilling of composite materials with various drill bits J. Mater. Process. Technol. 140 2003 335 339
45. H. Hocheng, and C.K.H. Dharan Delamination during drilling in composite laminates ASME J. Eng. Ind. 112 1990 236 239
46. A.B. Sadat, W.S. Chan, and B.P. Wang Delamination of graphite/epoxy laminate during drilling operation ASME J. E. Res. Technol. 114 1992 139 141
47. D. Bhattacharyya, and D.P.W. Horrigan A study of hole drilling in Kevlar composites Compos. Sci. Technol. 58 2 1998 267 283
48. L.B. Zhang, L.J. Wang, and X.Y. Liu A mechanical model for predicting critical thrust forces in drilling composite laminates Proc. Inst. Mech. Eng. Part B 215 2 2001 135 146
49. V. Chandrasekharan, S.G. Kappor, and R.E. DeVor A mechanistic approach to predicting the cutting forces in drilling: with application to fiber-reinforced composite materials ASME J. Eng. Ind. 117 1995 559 570
50. A. Langella, L. Nele, and A. Maio A torque and thrust prediction model for drilling of composite materials Compos. Part A 36 1 2005 83 93
51. R. Stone, and K. Krishnamurthy A neural network thrust force controller to minimize delamination during drilling of graphite-epoxy laminates Int. J. Machine Tools Manuf. 36 9 1996 985 1003
52. S. Jain, and D.C.H. Yang Effects of feedrate and chisel edge on delamination in composite drilling ASME J. Eng. Ind. 115 1993 398 405
53. S. Jain, and D.C.H. Yang Delamination-free drilling of composite laminates ASME J. Eng. Ind. 116 1994 475 481
54. E.J.A. Armarego, and J.D. Wright Predictive models for drilling thrust and torque - a comparison of three flank configurations Ann. CIRP 33 1984 5 10
55. D.A. Stephanson, and J.S. Agapiou Calculation of main cutting edge forces and torque for drills with arbitrary point geometries Int. J. Machine Tools Manuf. 32 4 1992 521 538
56. D.A. Budan, and S. Vijayarangan Quality assessment and delamination force evalution in drilling glass fiber-reinforced plastic laminates - a finite element analysis and linear elastic fracture mechanics approach Proc. Inst. Mech. Eng. Part B J. Eng. Manuf. 216 2 2002 173 182
57. N. Bhatnagar, I. Singh, and D. Nayak Damage investigation in drilling of glass fiber reinforced plastic composite laminates Mater. Manuf. Process. 19 6 2004 995 1007
58. H. Hocheng, and C.C. Tsao Analysis of delamination in drilling composite materials using step drill. Proceedings of 18th Conference Mechanical Engineering, no. (4) Taipei, Taiwan 2001 895 900
59. H. Hocheng, and C.C. Tsao Analysis of delamination in drilling composite materials using core drill Aust. J. Mech. Eng. 1 1 2003 49 53
60. K.F. Ehmann, S.G. Kapoor, R.E. DeVor, and I. Lazoglu Machining process modeling: a review ASME J. Manuf. Sci. Eng. 119 1997 655 659
61. C.A. Friend, R.W. Clyne, and G.G. Valentine Machining graphite composite materials B.R. Noton Composite Material Engineering Design 1973 ASM 217 224
62. V. Tagliaferri, A. Di Ilio, and I. Crivelli Visconti Laser cutting of fiber-reinforced polyesters Composite 16 4 1985 317 325
63. 2s aramid/epoxy laminates Composite 20 2 1989 115 119
64. G. Caprino, and V. Tagliaferri Maximum cutting speed in laser cutting of fiber reinforced plastics Int. J. Machine Tools Manuf. 28 4 1988 389 398
65. H. Hocheng A failure analysis of water jet drilling in composite laminates Int. J. Machine Tools Manuf. 30 3 1990 423 429
66. M. Hashish Machining of advanced composites with abrasive-water jets Manuf. Rev. 2 2 1989 142 160
67. G.E. Miller Special theory of ultrasonic machining J. Appl. Phys. 28 2 1957 149 156
68. V. Soundararajan, and V. Radhakrishnan An experimental investigation on the basic mechanisms involved in ultrasonic machining Int. J. Machine Tools Manuf. 26 3 1986 307 321
69. W.S. Lau, M. Wang, and W.B. Lee Electrical discharge machining of carbon fiber composite materials Int. J. Machine Tools Manuf. 30 2 1990 297 308
70. F. Mûller, and J. Monaghan Non-conventional machining of particle reinforced metal matrix composite Int. J. Machine Tools Manuf. 40 9 2000 1351 1366
71. P. Narender Singh, K. Raghukandan, M. Rathinasabapathi, and B.C. Pai Electric discharge machining of Al-10%SiCp as-cast metal matrix composites J. Mater. Process. Technol. 155/156 2004 1653 1657
72. H. Hocheng, W.T. Lei, and H.H. Hsu Preliminary study of material removal in electrical-discharge machining of SiC/Al J. Mater. Process. Technol. 63 1997 813 818
73. S. Abrate, and D.A. Walton Machining of composite materials Parts I and II: traditional and non-traditional methods Compos. Manuf. 3 2 1992 75 94
74. P.C. Upadhyay, and J.S. Lyons On the evaluation of critical thrust for delamination-free drilling of composite laminates J. Rein. Plast. Compos. 18 14 1999 1287 1303
75. H. Saghizadeh, and C.K.H. Dharan Delamination fracture toughness of graphite and aramid epoxy composites ASME J. Eng. Mater. Technol. 108 1986 290 295
76. C.K.H. Dharan Fracture mechanics of composite materials ASME J. Eng. Mater. Technol. 100 1978 233 247
77. S. Timoshenko, and S. Woinowsky-Keiger Theory of Plates and Shells second ed. 1959 McGraw Hill
78. C.C. Tsao, and H. Hocheng Analysis of delamination in drilling composite materials using core-center drill 11th ICCE Hilton Head, SC, USA 2004
79. H. Hocheng, and C.C. Tsao Analysis of delamination in drilling composite materials using core-saw drill 7th ICPMT Suzhou, China 2004 38 43
80. D. Liu Impact-induced delamination - a view of bending stiffness mismatching J. Compos. Mater. 22 1988 674 692
81. S.R. Swanson, and A.P. Christoforou Response of quasi-isotropic carbon/epoxy laminates to biaxial stress J. Compos. Mater. 20 1986 457 471
82. D.S. Cairns Static and dynamic mode II strain energy release rate in toughened thermosetting composite laminates J. Compos. Technol. Res. 14 1992 37 42
83. B.J. Long, and S.R. Swanson Ranking of laminates for edge delamination resistance Composite 25 3 1994 183 188
84. T.K. O'Brien, N.J. Johnston, D.H. Morris, and R.A. Simonds Simple test for the interlaminar fracture toughness of composites SAMPE J. 18 4 1982 8 15
85. N.J. Pagano, H.T. Hahn, Evaluation of composite curing stresses, composite materials: testing and design (4th conference) ASTM STP617 (1977) 317-329.
86. W. Hwang, and K.S. Han Interlaminar fracture behavior and fiber bridging of glass-epoxy composite under mode I static and cyclic loadings J. Compos. Mater. 23 1989 396 430
87. S.W. Tsai Composites Design 1986 Think Composites Dayton, OH
88. G. DiPaolo, S.G. Kapoor, and R.E. DeVor An experimental investigation of the crack growth phenomenon for drilling of fiber-reinforced composite materials ASME J. Eng. Ind. 118 1996 104 110
89. C.C. Tsao, and H. Hocheng The effect of chisel length and associated pilot hole on delamination when drilling composite materials Int. J. Machine Tools Manuf. 43 11 2003 1087 1092
90. M.S. Won, and C.K.H. Dharan Chisel edge and pilot hole effects in drilling composite laminates ASME J. Manuf. Sci. Eng. 124 2002 242 247
91. C.C. Tsao, and H. Hocheng Effects of exit back-up on delamination in drilling composite materials using a saw drill and a core drill Int. J. Machine Tools Manuf. 45 11 2005 1261 1270
92. R.B. Adams, Waterjet machining of composites, Composites in Manufacturing, SME Paper EM86-113, 1986.
93. M.C. Shaw Ultrasonic grinding Microtechnic 10 6 1956 257 265
94. M.A. Moreland Ultrasonic impact grinding: What it is: What it will do Proceedings on 22nd Abra. Engineering Society Conference 1984 111 117
95. E.W. Pentland, and J.A. Ektermanis Improving ultrasonic machining rates - some feasibility studies ASME J. Eng. Ind. 87 1965 39 46
96. V. Soundararajan, and V. Radhakrishnan An experimental investigation on the basic mechanisms involved in ultrasonic machining Int. J. MTDR 26 3 1986 307 321
97. D.C. Kennedy, and R.J. Grieve Ultrasonic machining - a review Proc. Eng. 54 9 1975 481 486
98. L.D. Rozenberg, V.F. Kazemtsev, L.O. Makrov, and D.F. Yakhimovich Ultrasonic Cutting 1964 Consultants Bureau New York
99. D. Kremer The state of the art of ultrasonic machining Ann. CIRP 30 1981 107 110
100. H. Hocheng, and C.C. Hsu Preliminary study of ultrasonic drilling of fiber-reinforced plastics J. Mater. Process. Technol. 48 1995 255 266
101. H. Dam, and P. Quist Productivity, surface quality and tolerances in ultrasonic machining of ceramics J. Mater. Process. Technol. 51 1995 358 368
102. T.B. Thoe, D.K. Aspinwall, and M.L.H. Wise Review on ultrasonic machining Int. J. Machine Tools Manuf. 38 4 1998 239 255
103. W.E. Lawson Laser cutting of composite Compos. Manuf. (SME LA, USA) 1986 1 10
104. M.D. Mello Laser cutting of non-metallic composites Proceedings SPIE - Laser Processing: Fundamentals, Applications and Systems Engineering, vol. 668 1986 288 290
105. S.G. Howarth, and A.B. Strong Edge effects with waterjet and laser beam cutting of advanced composite materials 35th International SAMPE Symposium 1990
106. C.T. Pan, and H. Hocheng Prediction of extent of heat affected zone in laser grooving of unidirectionally fiber-reinforced plastics ASME J. Eng. Mater. Technol. 120 1998 321 327
107. E. Uhlmann, G. Spur, H. Hocheng, S. Liebelt, and C.T. Pan The extent of laser-induced thermal damage of fiber UD and cross-ply composite laminates Int. J. Machine Tools Manuf. 39 4 1999 639 650
108. C.T. Pan, and H. Hocheng Evaluation of anistropic thermal conductivity for unidirectional fiber-reinforced plastics in laser machining of unidirectionally fiber-reinforced plastics Compos. Part A 32 11 2001 1657 1667
109. I.P. Tuersley, T.P. Hoult, and I.R. Pashby Nd-YAG laser machining of SiC fibre/borosilicate glass composites. Part II - the effect of process variables Compos. Part A 29 8 1998 955 964
110. W.S.O. Rodden, S.S. Kudesia, D.P. Hand, and D.C. Jones A comprehensive study of the long pulse Nd:YAG laser drilling of multi-layer carbon fibre composites Opt. Commun. 210 3-6 2002 319 328
111. B. Tan, K. Venkatkrishnan, N.R. Sivakumar, and G.K. Gan Laser drilling of thick material using femtosecond pulse with a focus of dual-frequency beam Opt. Laser Technol. 35 3 2003 199 202
112. S. Tandon, V.K. Jain, P. Kumar, and K.P. Rajurkar Investigations into machining of composites Prec. Eng. 12 4 1990 227 238
113. V.K. Jain, S. Tandon, and P. Kumar Experimental investigations into electrochemical spark machining of composites ASME J. Eng. Ind. 112 1990 194 197
114. V.K. Jain, P. Sreenivasa Rao, S.K. Choudhary, and K.P. Rajurkar Experimental investigations into traveling wire electro-chemical spark machining (TW-ECSM) of composites ASME J. Eng. Ind. 113 1991 75 84
115. L.J. Wang, and Z. Ji Kinematics and surface roughness in turning with ultrasonic vibration tool J. Arms 9 8 1987 24 31
116. J. Ramkumar, S.K. Malhotra, and R. Krishnamurthy Effect of workpiece vibration on drilling of GFRP laminates J. Mater. Process. Technol. 152 3 2004 329 332
117. Q.X. Zhang, and S. Sun Study on ultrasonic vibration drilling in carbon fiber reinforced polymers Chin. J. Mech. Eng. 7 1 1994 72 77
118. L.B. Zhang, L.J. Wang, X.Y. Liu, H.W. Zhao, X. Wang, and H.Y. Luo Mechanical model for predicting thrust and torque in vibration drilling fiber-reinforced composite materials Int. J. Machine Tools Manuf. 41 5 2001 641 657
119. L.P. Wang, and L.J. Wang Prediction and computer simulation of dynamic thrust and torque in vibration drilling Proc. Inst. Mech. Eng. Part B 212 6 1998 489 497
120. L.B. Zhang, L.J. Wang, and X. Wang Study on vibration drilling of fiber reinforced plastics with hybrid variation parameters method Compos. Part A 34 3 2003 237 244
121. X. Wang, L.J. Wang, and J.P. Tao Investigation on thrust in vibration drilling of fiber-reinforced plastics J. Mater. Process. Technol. 148 2 2004 239 244