Drilling is one of the most frequent machining operations for carbon fiber-reinforced polymer composites, carried out prior to assembly between structural components using mechanical joining. Delamination is the main damage mechanism involved during carbon fiber-reinforced polymer composite drilling causing an elevated percentage of workpiece rejection. Tool geometry strongly influences drilling performance. In this paper, an original work dealing with the comparison between three recently developed configurations (Brad center, Step drill and Reamer drills) in terms of drilling forces and delamination both for woven and tape carbon fiber-reinforced polymers is presented. Reamer drill showed the best results concerning productivity and delamination. Strong differences were found when hole quality obtained in tape and woven composite was compared: multidirectional composite presented poorer hole quality than woven composite under the same cutting conditions. The analysis of variance was developed in order to analyze the influence of each parameter showing the importance of feed rate on surface damage.
López De LacalleNLamikizACampaFJ. Design and test of a multitooth tool for CFRP milling. J Compos Mater2009; 43: 3275–3290.
4.
GirotFIliescuDValdiviesoAF. Experimental study and modelling of tool wear during drilling and trimming of CFRP. Revue des Composites et des Materiaux Avances2013; 23: 357–385.
5.
SantiusteCBarberoEMiguélezMH. Computational analysis of temperature effect in composite bolted joints for aeronautical applications. J Reinf Plast Compos2011; 30: 3–11.
6.
SantiusteCOlmedoASoldaniX. Delamination prediction in orthogonal machining of carbon long fiber-reinforced polymer composites. J Reinf Plast Compos2012; 31: 875–885.
7.
KrishnarajVZitouneRDavimJP. Drilling of polymer-matrix composites, Heidelberg: Springer, 2013.
8.
DavimJP. Drilling of composite materials, New York: NOVA Publishers, 2009.
9.
FeitoNLópez-PuenteJSantiusteC. Numerical prediction of delamination in CFRP drilling. Compos Struct2014; 108: 677–683.
10.
AbrãoAMCampos RubioJCFariaPE. The effect of cutting tool geometry on thrust force and delamination when drilling glass fibre reinforced plastic composite. Mater Des2008; 29: 508–513.
11.
GaitondeVNKarnikSRCamposJ. Analysis of parametric influence on delamination in high-speed drilling of carbon fiber reinforced plastic composites. J Mater Process Technol2008; 203: 431–438.
12.
CamposJAbrãoAMFariaPE. Effects of high speed in the drilling of glass fibre reinforced plastic: evolution of the delamination factor. Int J Mach Tools Manuf2008; 48: 715–720.
13.
DavimJPCamposJAbrãoAM. A novel approach based on digital analysis to evaluate the delamination factor after drilling composite laminates. Compos Sci Technol2007; 67: 1939–1945.
MarquesTDurãoMMagalhãesA. Delamination analysis of carbon fibre reinforced laminates: evaluation of a special step drill. Compos Sci Technol2009; 69: 2376–2382.
16.
ShyhaSAspinwallDKSooSL. Drill geometry and operating effects when cutting small diameter holes in CFRP. Int J Mach Tools Manuf2009; 49: 1008–1014.
17.
PiquetRLachaudFFerretB. Experimental analysis of drilling damage in thin carbon/epoxy plate using special drills. Compos Part A2000; 31: 1107–1115.
18.
XuJAnQChenM. A comparative evaluation of polycrystalline diamond drills in drilling high-strength T800S/250F CFRP. Compos Struct2014; 117: 71–82.
19.
KarpatYBahtiyarODegerB. A mechanistic approach to investigate drilling of UD-CFRP laminates with PCD drills. CIRP Ann – Manuf Tech2014; 63: 81–84.
20.
DavimJPReisP. Drilling carbon fiber reinforced plastics manufactured by autoclave-experimental and statistical study. Mater Des2003; 24: 315–324.
21.
GriloTJPauloRMFSilvaCRM. Experimental delamination analyses of CFRPs using different drill geometries. Compos Part B2013; 45: 1344–1350.
22.
HochengHTsaoCC. Effects of special drill bits on drilling-induced delamination of composite materials. Int J Mach Tools Manuf2006; 46: 1403–1416.
23.
TsaoCC. Experimental study of drilling composite materials with step-core drill. Mat Des2008; 29: 1740–1744.
24.
TsaoCCChiuYC. Evaluation of drilling parameters on thrust force in drilling carbon fiber reinforced plastic (CFRP) composite laminates using compound core-special drills. Int J Mach Tools Manuf2011; 51: 740–744.
25.
LazarMBXirouchakisP. Experimental analysis of drilling fiber reinforced composites. Int J Mach Tools Manuf2011; 51: 937–946.
26.
ShyhaSSooLAspinwallD. Effect of laminate configuration and feed rate on cutting performance when drilling holes in carbon fibre reinforced plastic composites. J Mater Process Technol2010; 210: 1023–1034.
27.
MurphyCByrneGGilchristMD. The performance of coated tungsten carbide drills when machining carbon fibre-reinforced epoxy composite materials. Proc Instn Mech Engrs, Part B: J Eng Manuf2002; 216: 143–152.
28.
Sandvik Coromant. Modern metal cutting: a practical handbook. 1st ed. North American, Sandviken, Sweden: Sandvik Coromant, 1994.
29.
Ramirez C, Poulachon G, Rossi F, et al. Tool wear monitoring and hole surface quality during CFRP drilling. In: Procedia CIRP (ed.) 2nd conference on surface integrity (CSI), Nottingham, UK, 28 May–30 May 2014, pp. 163–168.
30.
MondelinAFuretBRechJ. Characterisation of friction properties between a laminated carbon fibres reinforced polymer and a monocrystalline diamond under dry or lubricated conditions. Tribol Int2010; 43: 1665–1673.
31.
FeitoNDíaz-ÁlvarezJDíaz-ÁlvarezA. Experimental analysis of the influence of drill point angle and wear on the drilling of woven CFRPs. Mater2014; 7: 4258–4271.
32.
FarazABiemannDWeinertK. Cutting edge rounding: an innovative tool wear criterion in drilling CFRP composite laminates. Int J Mach Tools Manuf2009; 49: 1185–1196.
33.
WangaXKwonaPYSturtevantbC. Tool wear of coated drills in drilling CFRP. J Manuf Processes2013; 15: 127–135.
34.
Díaz-ÁlvarezJOlmedoASantiusteC. Theoretical estimation of thermal effects in drilling of woven carbon fiber composite. Mater2014; 7: 4442–4454.
35.
SantiusteCDíaz-ÁlvarezJSoldaniX. Modelling thermal effects in machining of carbon fiber reinforced polymer composites. J Reinf Plast Compos2014; 33: 758–766.
Ridgard C. Complex structures for manned/unmanned aerial vehicles. Low temp composite processing mechanical property data. Air Force Research Laboratory. AFRL-RX-WP-TM-2008-4054; 2008.
40.
Varas D, Artero-Guerrero JA, Pernas-Sánchez J, et al. Analysis of high velocity impacts of steel cylinders on thin carbon/epoxy woven laminates. Compos Struct 2013; 95: 623–629.
