International E-publication: Publish Projects, Dissertation, Theses, Books, Souvenir, Conference Proceeding with ISBN.  International E-Bulletin: Information/News regarding: Academics and Research

Applying Wear Maps in the Optimisation of Machining Parameters in Drilling of Polymer Matrix Composites - A Review

Author Affiliations

  • 1Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal, INDIA

Res. J. Recent Sci., Volume 1, Issue (5), Pages 75-82, May,2 (2012)


The use of polymeric composite materials (CFRP and GFRP) has increased considerably in aerospace engineering,automobile engineering, medical applications and structural application etc. over the last decade. These developments leadto an increase in the number of technical research papers focusing on relevant aspects concerning the machining of suchmaterials. In conventional machining, drilling is the most applied method accounting for as much as 40% of all materialremoval processes. However, problems in composite material drilling, particularly the heterogeneity and anisotropy ofcomposite materials, increase delamination, surface roughness and tool wear etc. makes the machining more complexcompared to metal machining. It was also investigated that drilling of fibre reinforced composites with conventional toolsoften results in defects like fiber debonding, fibre pullout, etc. Therefore the principal aim of this research paper is to screen through the literature on machining of composite materials, more specifically on drilling of glass/carbon fibre reinforcedepoxy composites focusing on the factors such as tool materials and geometry, machining parameters and their influence onthe tool wear. In this particular context, many researchers have worked on metals, conducting series of experiments on tool wear and wear rate, and developed the wear mechanism map for different combinations of cutting tools and metals in order to optimize process parameters. Lack of research work has been recorded so far on the tool wear mapping of drills on composite materials. This made the authors to develop the different wear mechanisms during drilling of polymer matrix composites so as to arrive at “safety zone” process parameters. Also, the observations and outcomes of this research paper would significantly contribute to the methodology that can be adopted to find the wear mechanism of drill bit while machining polymer matrix composite materials and the findings of this study can lead to the identification of improved and optimised operational parameters.


  1. Adam, Jin Jiang and Peter, machining composite materials,Wear, (1997)
  2. Sang-Ook An, Eun-Sang Lee, Sang-Lai Noh, A study on the cutting characteristics of glass fibre reinforced plastics with respect to tool materials and geometries, Journal of Materials processing technology, 68, 60-67 (1997)
  3. Williams J.A., Wear modeling: analytical, computational and mapping: a continuum mechanics approach, Wear,225-229, 1-17 (1999)
  4. Chowdhury S.K., and Ganga Raju, Investigation into crater wear in drilling, International Journal of Machine tools and Manufacture, 40, 887-898 (2000)
  5. Zhang M.Z., Liu, Y.B., and Zhou, H., Wear mechanism maps of uncoated HSS tools drilling die-cast Aluminium alloy, Tribology International, 34(11), 727-731 (2001)
  6. Lim C.Y.H., Lau P.P.T., Lim S.C., The effect of work material on tool wear, Wear, 250, 344-348 (2001)
  7. Ugo E., Enemuoh A., Sherif El-Gizawy A. and Chukwujekwu Okafor, An approach for development of damage-free drilling of carbon fiber reinforced thermosets, International Journal of Machine Tools andManufacture, 41 1795–1814 (2001)
  8. Nouari M., List G., Girot F., and Coupard D., Experimental analysis and optimization of tool wear in dry machining of Aluminium alloys, Wear, 255, 1359-1368 (2003)
  9. Nouari M., List G., Girot F. and Gehin D., Effect of machining parameters and coating on wear mechanisms in dry drilling of aluminium alloys, International Journal of Machine Tools andManufacture, 45 436–1442 (2005)
  10. Abrao A.M., Faria P.E., Campos Rubio J.C., Reis P. and Paulo Davim J., Drilling of Fiber Reinforced plastics- A review, Journal of Materials Processing Technology, 186, 1-7 (2007)
  11. Mustafa Kurt and Eyup Bagci andYusuf Kaynak, Application of Taguchi methods in the optimization of cutting parameters for surface finish and hole diameter accuracy in dry drilling processes, International Journal of Advanced Manufacturing Technology (2007)
  12. Wang J., Liu Y.B., An J., and Wang L.M., Wear mechanism map of uncoated HSS tools during drilling diecast magnesium alloy, Wear, 265, 685-691 (2008)
  13. Faria P.E., Campos Rubio J.C. and Abrao A.M., Dimensional and Geometric Deviations Induced by Drilling of Polymeric Composite, Journal of Reinforced Plastics And Composites, 28(19), (2009)
  14. Cakir M.C., and Gurarda, A., Optimization of machining conditions for multi-tool milling operations, International Journal of Production Research, 38(15), 3537–3552 (2009)
  15. Al-Wedyan, H., Demirli, K., andBhat, R. A technique for fuzzy logic modelling of machining process. 20th NAFIPS international conference: vol. 5, (2009), pp. 3021–3026.