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

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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)

Abstract

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.

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