Experimental thrust forces and delamination analysis of GFRP laminates using candlestick drills

Drilling is usually performed using twist drills while assembling the composite components. However, it is necessary to adopt appropriate tool as the risk of delamination damage is high. Many researchers have performed experimental and theoretical study concerning drilling-induced delamination damage in composites utilizing special drills. The article performed drilling experiments of glass fiber reinforced plastic laminates utilizing candlestick drills. Ten candlestick drills with different drill tip geometries were compared in thrust forces and push down delamination. The results revealed the drilling behavior of the outer cutting edges and the outer drill tips for candlestick drill, and also indicated that the push down delamination depended on exit thrust force instead of maximum thrust force. What is more, thrust forces and push down delamination were significantly reduced when holes were produced using reasonable candlestick drill tip geometry. Finally, the analysis was useful for selecting appropriate candlestick drill tip geometry and conducting candlestick drill tip geometry optimization.     

Impact and post-impact damage characterisation of hybrid composite laminates based on basalt fibres in combination with flax,hemp and glass fibres manufactured by vacuum infusion

The impact and flexural post-impact behaviour of ternary hybrid composites based on epoxy resin reinforced with different types of fibres, basalt (B), flax (F), hemp (H) and glass (G) in textile form, namely FHB, GHB and GFB, has been investigated. The reinforcement volume employed was in the order of 21–23% throughout. Laminates based exclusively on basalt, hemp and flax fibres were also fabricated for comparison. Hybrid laminates showed an intermediate performance between basalt fibre reinforced laminates on the high side, and flax and hemp fibre reinforced laminates on the low side. As for impact performance, GHB appears to be the worst performing hybrid laminate and FHB slightly overperforms GFB. In general, an increased rigidity can be attributed to all hybrids with respect to flax and hemp fibre composites. The morphological study of fracture by SEM indicated the variability of mode of fracture of flax and hemp fibre laminates and of the hybrid configuration (FHB) containing both of them. Acoustic emission monitoring during post-impact flexural tests confirmed the proneness to delamination of FHB hybrids, whilst they were able to better withstand impact damage than the other hybrids.     

Delamination in drilling GFR-thermoset composites

Delamination is a major problem associated with drilling fiber-reinforced composite materials that, in addition to reducing the structural integrity of the material, also results in poor assembly tolerance and has the potential for long-term performance deterioration. Delamination-free in drilling different fiber reinforced thermoset composites is the main objective of the present paper. Therefore the influence of drilling and material variables on thrust force, torque and delamination of GFRP composites was investigated experimentally. Drilling variables are cutting speed and feed. Material variable include matrix type, filler and fiber shape. Drilling process was carried out on cross-winding/polyester, continuous-winding with filler/polyester, chopped/polyester, woven/polyester and woven/epoxy composites. A simple inexpensive accurate technique was developed to measure delamination size.

The results show that the presence of sand filler in continuous-winding composites not only raised the values of cutting forces and push-out delamination but also increased their values with increasing cutting speed. In contrast, increasing the cutting speed in drilling cross-winding, woven and chopped composites reduces the push-out delamination as a result of decreasing the thrust force. The thrust forces in drilling continuous-winding composite are more than three orders of magnitude higher than those in the cross-winding composites. Chopped composites have lower push-out delamination than those made from woven fibers. For the same fiber shape, the peel-up and push-out delaminations of woven/epoxy composite are lower than that for woven/polyester composites. Delamination, chipping and spalling damage mechanisms were observed in drilling chopped and continuous-winding composites. In drilling woven composites the delamination was observed at different edge position angles due to the presence of the braids that made by the interlacing of two orthogonal directions of fibers tows (warp and fill). Delamination-free in drilling cross-winding composites was achieved using variable feed technique.     

Low velocity response of a complex geometry pultruded glass/polyester composite

This paper describes an investigation into the low velocity impact response on complex geometry sections taken from a pultruded glass/polyester product. The empirical impact behaviour of the system was evaluated using instrumented falling weight impact testing (IFWI) in conjunction with ultrasonic C-Scan, optical microscopy and thermal deply techniques to detect delamination, matrix cracking, and fibre breakage.     

Low velocity response of simple geometry pultruded glass/polyester composite

This paper describes an investigation into the low velocity impact response of relatively simple geometry coupons taken from a pultruded glass/polyester product. The pultruded lay-up is a typical three ply design – a unidirectional fibre ply sandwiched between two continuous filament mat plies. By employing a simple geometry the impact response under transverse and longitudinal bending, and shear loading are considered. Impact tests from low energy through to final failure were conducted using the instrumented falling weight impact test technique. Through a detailed analysis involving ultrasonic C-scan, optical microscopy, and thermal deply all the major damage modes (delamination, fibre breakage and matrix cracking) were related to the force-deflection responses.     

Analysis of delamination in drilling glass fiber reinforced polyester composites

Glass fiber reinforced plastic (GFRP) composite materials are finding increased application in aeronautical, automobile and structural applications. Drilling is a complex process, owing to their tendency to delaminate is used to join composite structures. In the present work, an attempt has been made to develop empirical relationships between the drilling parameters such as fiber orientation angle, tool feed rate, rotational speed and tool diameter with respect to delamination in drilling of GFR–polyester composites. The empirical relationship has been developed by using response surface methodology. The developed model can be effectively used to predict the delamination in drilling of GFRP composites within the factors and their limits are studied. The result indicated that the increase in feed rate and drill diameter increases the delamination size whereas there is no clear effect is observed for fiber orientation angle. The spindle speed shows only little effect on delamination in drilling of GFR–Polyester composites.     

Experimental investigation on drilling of natural flax fiber-reinforced composites

Natural fiber composites (NFCs) have strong potential to replace glass fiber-reinforced plastics. An instrumental operation in machining composite structures is hole making which facilitates assembly of parts. Understanding the effects of drilling process parameters on feature properties of NFCs has great benefits. In this regard, to make a good quality and accurate hole in composite structures, appropriate selection of drill bit and cutting parameters is important. This paper investigates delamination behavior and hole quality of flax/epoxy composite laminates in response to feed, spindle speed, and three different types of drill bit. As indicated by analysis of variance results, drill bit type and feed have greater influences on the thrust force. It appeared that delamination factor and surface roughness were significantly influenced by drill bit, but not by feed and spindle speed. The choice of drill bit has great impact on the delamination factor (67.27%) and surface roughness (74.44%), respectively.     

An approach towards damage free machining of CFRP and GFRP composite material: a review

Over the last decade, the use of polymeric composite material has increased considerably, and as a result, machinability of such material has also increased. The main aim of this work is to emphasize on the conventional and unconventional machining of composite materials, more specifically on drilling of carbon fiber-reinforced polymer and glass fiber-reinforced polymer. Additional concentration on tool materials and geometry, roughness of drill surface, thrust force and delamination at entry and exit with influence of point angle of tool, variable feed rate, and variable spindle speed. Over the last few years, many studied on the effect of cutting parameters and tool geometry using conventional machining, the phenomena associated with unconventional machining of composite material requires some supplementary studies in order to make damage free machining of composite materials.     

Delamination and Surface Roughness Analyses in Drilling Hybrid Carbon/Glass Composite

Previous attempts at drilling of fibrous composites have been challenging due to the limited mechanical properties and presence of severe delamination damage at the top and bottom surfaces of the drilled hole. With the recent introduction of hybrid carbon/glass fiber reinforced polymer (HFRP) composites in both research literature and industrial applications, the need for evaluating their drillability is inevitable prior to their final usage. This is mainly because of the unique properties of HFRP composites as compared to the single-type FRP composites. Therefore, this paper aims to present a research initiative that will elucidate the high-range parametric effects of drilling control factors on delamination damage and surface quality. Taguchi methodology and statistical analysis of variance were applied to determine the performance of the drilling process. Experimental results revealed that delamination damage and surface quality values were strongly influenced by the feed and special tool geometries rather than the spindle rotational speed. Changes in the feed are likely to contribute to increase in the thrust force and strain rate on the workpiece. Confirmation tests have shown the closeness of the calculated values via a regression model and additive rule with the experimental values. This indicates that the regression model from the response surface can be employed to estimate delamination damage and surface roughness during drilling of HFRP composite.     

Flexural behaviour of hybrid laminated composites

The present paper studies the flexural behaviour of hand manufactured hybrid laminated composites with a hemp natural fibre/polypropylene core and two glass fibres/polypropylene surface layers at each side of the specimen. When compared with full glass fibres reinforced polypropylene laminates, the hybrid composites have economical, ecological and recycling advantages and also specific fatigue strength benefits. Static and fatigue tests were performed in three point bending for both laminates to evaluate flexural strength properties and fatigue behaviour. Fatigue damage was measured in terms of the stiffness loss. Failure sites and mechanisms were evaluated through microscopy studies and a 3D numerical analysis using finite element method.     

Analysis of fracture mechanisms and surface quality in drilling of composite materials

The aim of this work is to clarify the interaction mechanisms between the drilling tool and material. Drilling tests were carried out on glass/polyester and carbon/epoxy composites using different twist drills. The cutting tools and machined surfaces were examined by optical microscopy, scanning microscopy and surface profilometry to study composite damage and tool wear. Among the defects caused by drilling, delamination appears to be the most critical and may occurs at both the entrance and exit planes. A prediction model of thrust force for drilling without delamination is proposed. __________ Translated from Problemy Prochnosti, No. 1, pp. 48–51, January–February, 2008.     

Influence of adsorption behaviour of a silane coupling agent on interlaminar fracture in glass fibre fabric-reinforced unsaturated polyester laminates

The relationship between the interphase consisting of physisorbed and chemisorbed silane on glass fibres and the resultant composite Mode I delamination fracture toughness in glass fibre fabric laminate, was studied. The Mode I interlaminar fracture toughness of the laminate specimen was obtained by using a double cantilever beam (DCB) specimen. The delamination resistance of the laminate specimen finished with two silane concentrations and washed in methanol solvent, is discussed on the basis of the interlaminar fracture toughness. In order to determine the amount of physisorbed and chemisorbed silane on the glass fibre, the amount of total carbon was determined using an analysis instrument. The physisorbed silane migrated into the resin matrix and influenced the mechanical properties and interlaminar fracture of the laminate specimen. The amount of unsaturated polyester resin blended with a silane coupling agent was measured using dynamic mechanical spectroscopy, and a DCB specimen for mechanical properties and fracture toughness.     

Influence of redmud on the mechanical,damping and chemical resistance properties of banana/polyester hybrid composites

A novel hybrid composite was developed with the addition of redmud as secondary reinforcing filler with banana fiber reinforced polyester composites (BFRPCs). The effect of varying parameters such as particle size (4, 6 and 13 μm) and weight percentage (2, 4, 6, 8 and 10 wt%) of redmud were analyzed on static mechanical, free vibration and chemical resistance properties of hybrid composites. The addition of redmud shown enhanced performance compared to the virgin BFRPCs in all the above said properties. The maximum increase of 50% in mechanical strength was observed for the BFRPCs with the addition of redmud having 4 μm particle size and 8 wt% of filler content compared to pure BFRPCs. The increased value of fundamental natural frequencies with associated modal damping characteristics of redmud filled BFRPCs were found using half-power band width method. All the fabricated composites performed well against various chemicals and it indicates that the resistance to the weight loss is due to the uniformly distributed redmud. To study the effect of redmud on interfacial bonding between the banana fiber and polyester matrix the Scanning Electron Microscope (SEM) image analysis was performed.     

Optimum bolted joints for hybrid composite materials

The optimum bolted joints for hybrid composite materials composed of glass-epoxy and carbon-epoxy under tensile loading were investigated. The design parameters considered for the bolted joints were ply angle, stacking sequence, the ratio of glass-epoxy to carbon-epoxy, the outer diameters of washers and the clamping pressure. As bearing failure was desirable for bolted joints, the geometry of the bolted joint specimen was designed to undergo bearing failure only.

By inspecting the fracture surfaces of the specimens it was found that delamination on the loaded periphery of the holes and extensive damage on the edge region constrained by a washer occurred. To assess the delamination of the hybrid composite materials, three-dimensional stress analysis of the bolted joint was performed using a commercial finite-element software and compared with the experimental results.     

Tamarind Fruit Fiber and Glass Fiber Reinforced Polyester Composites

Polyester-based hybrid composites were developed by combining the tamarind fruit (Tf) and glass fibers into a polyester matrix. Hardness, impact strength, frictional coefficient, and chemical resistance of hybrid composites with and without alkali treatments were studied. Variation of the aforementioned mechanical properties and chemical resistance was studied with different fiber lengths, such as 1, 2, and 3 cm. A 9 vol% of the tamarind and glass fibers was reinforced into the polyester matrix. The aforementioned mechanical properties were optimally improved at 2-cm fiber length when compared with 1- and 3-cm fiber lengths. Chemical resistance was also significantly improved for all chemicals except toluene. A 3°C rise in decomposition temperature while a 2°C rise in glass transition temperature was observed from TGA and DSC micrograms, respectively.     

Trepanning on unidirectional composites: delamination studies

Drilling of fibre reinforced plastics with conventional tools often results in defects like delamination, debonding, fibre pull-out, etc. Thrust is a major factor responsible for delamination and it mainly depends on tool geometry and feed rate. Trepanning tools, which were used in this study, were found to give reduced thrust while making holes on thin laminated composites. In this work the peculiarities of trepanning over drilling of unidirectional composites has been emphasised. The models for prediction of critical thrust and critical feed rate at the onset of delamination during trepanning of unidirectional composites based on fracture mechanics and plate theory also have been presented. Mathematical models correlating thrust and torque with tool diameter and feed rate have been developed through statistically designed experiments and effect of various parameters on them have been discussed. The critical feed rate is a function of strain energy release rate, elastic properties, sub-laminate thickness and diameter of the tool. It is observed that sub-laminate thickness is the most decisive parameter from the viewpoint of critical feed rates.     

多齿铣刀侧铣加工多层CFRP铣削力的建模与仿真

由于碳纤维增强树脂基复合材料(CFRP)的层间结合强度较低,进行切削加工时在切削力的作用下容易出现分层和毛刺等质量缺陷。因此,通过对切削力的预测与控制可以有效提高加工质量。采用瞬时刚性力模型对多齿铣刀侧铣多层CFRP材料的加工过程进行铣削力建模与仿真,分析了多齿铣刀特有的几何结构对切削力的影响。试验中保持切削速度恒定,以不同进给速度分别对45°、0°、-45°和90°这4种典型纤维方向的单向CFRP进行侧铣加工,通过测得的切削力数据计算各自的铣削力系数。根据力学矢量叠加原理得到了多向CFRP铣削力系数的简化计算表达式,最后将计算结果代入铣削力模型得到了各时刻的铣削力仿真值。在同样的试验条件下对该多向CFRP进行侧铣加工验证试验,试验结果表明: 该模型能较好地预测铣削力,最大相对误差小于9%,平均相对误差小于5%,可为铣削参数优化和刀具结构优化提供理论基础。     

Delaminationsverhalten von langfaserverstärkten thermoplastischen UD-Verbunden hergestellt aus unterschiedlichen Hybridgarnstrukturen

Characterisation of the delamination behaviour of thermoplastic UD-composites made by different hybrid yarn structures In order to determine delamination behaviour of glass-fibre-reinforced polyamid composites the compression shear test and the DCB (Double Cantilever Beam)-, SEN- and NBT-test for mode-I- and the ENF (End Notched Flexure)-test for mode II-loading were used. By these tests the energy release rate G respectively K and the R cure (crack resistance curve) have been measured which characterise the crack resistance of the material against delamination. The composites were made by different hybrid yarn structures produced by air texturing (commingled yarn: COM), side-by-side arrangement (SBS), friction spinning (FS), Kemafil (KEM)- and Schappe(SCH)-technology. The influence of different glass fibre sizings was investigated. The results demonstrate the significant influence of different hybrid yarn structures and glass fibre coatings on fracture thoughness during crack propagation along the fibre/matrix interface. The best values were obtained for composites produced on the basis of commingled yarn structure.     

Drilling tool geometry evaluation for reinforced composite laminates

In this work, a comparative study on different drill point geometries and feed rate for composite laminates drilling is presented. For this goal, thrust force monitoring during drilling, hole wall roughness measurement and delamination extension assessment after drilling is accomplished. Delamination is evaluated using enhanced radiography combined with a dedicated computational platform that integrates algorithms of image processing and analysis. An experimental procedure was planned and consequences were evaluated. Results show that a cautious combination of the factors involved, like drill tip geometry or feed rate, can promote the reduction of delamination damage.     

Influence of fibre treatment and glass fibre hybridisation on thermal degradation and surface energy characteristics of hemp/unsaturated polyester composites

The effect of fibre treatment on the thermal degradation and surface energy characteristics of hemp fibre reinforced unsaturated polyester (HFRUP) composites was investigated by means of a thermogravimetric analyser (TGA) in a nitrogen atmosphere and contact angle measurement. In order to modify the fibre/matrix interface, NaOH treatment and glass fibre hybridisation were employed. HFRUP composites were compared to the unreinforced UP, NaOH treated hemp and glass fibre hybridised hemp/UP composites. TGA test results show that the weight loss for all samples occurred between 200 and 415 °C. The unreinforced UP had a maximum weight loss of 1.011%/°C. For the HFRUP composites, the maximum rate of weight loss was 0.81%/°C. For the NaOH treated and glass fibre hybridised hemp/UP composites, the maximum rate of weight loss was 0.78%/°C and 0.79%/°C, respectively. The effect of fibre treatment on the surface energy of studied samples and their dispersive and polar components were also investigated. Surface energy characteristics obtained from contact angle measurement revealed that for unreinforced UP, the contact angle measured with glycerol is 49.37°. For hemp/UP composites, the contact angle is 76.05°. For NaOH treated hemp/UP composites sample, the contact angle was recorded 78.89°, higher than untreated one. For hemp/CSM/UP specimen, the contact angle was recorded 69.80°. Both TGA and contact angle results indicated that surface treatment and glass fibre hybridisation led to better thermal stability and the wetting behaviour of hemp/UP composites.