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.     

Investigations on drilling of hemp/glass hybrid composites

The present study aimed to examine the influence of tool geometry, spindle speed and feed on thrust force (TF) and delamination in hybrid hemp-glass composites. The pure glass polyester, pure hemp polyester and hybrid hemp/glass polyester composite specimens were prepared using hand layup technique. The drilling experiments were performed according to the full factorial design. Analysis of variance (ANOVA) was used to determine the impact of layering arrangement of fibers, feed (0.06, 0.18, 0.3?mm/rev), speed (1000, 3000, 5000?rpm), tool geometry (Plexi Point, Brad, Parabolic) and their interactions on TF and delamination. It was observed that drill geometry is major determinant for TF and delamination. Empirical models were developed using regression analysis and grey relational analysis was performed for optimizing the input parameters for TF and delamination at entry and exit.     

A new delamination pattern in elevated-temperature oxidative wear

The sliding wear tests were performed under the atmospheric conditions at 400 °C for H13 steel. The effects of load on the wear mechanisms and delamination patterns were studied. A new delamination pattern was found to appear in the mild-severe transition region of the elevated-temperature wear. The delamination pattern could be proved by the belt-like debris and the corresponding wide ditches on worn surfaces. Under the loads of 50–100 N, mild oxidative wear prevailed with the characteristics of the plate-like oxide debris and low wear loss and its delamination was from inside oxides or the interface between the oxides and bulk metal. The wear rate increased with increasing load; the mild–severe wear transitions occurred under the loads of 100–200 N concomitant with more and more belt-like debris and wide ditches on worn surfaces. In this case, the wear loss would be mainly attributed to a special delamination from inside the bulk metal underneath the tribo-oxides with the formation of belt-like debris containing oxide and bulk metal. The delamination pattern was realized by the way that the ploughed furrows were first formed by the micro-cutting of oxide particles in the delaminated zone, whereby cracks initiate from the furrow wall and propagate parallel to worn surface to cause the delamination.     

A finite element model for the analysis of buckling driven delaminations of thin films on rigid substrates

The delamination process of thin films on rigid substrates is investigated. Such systems are typically subject to high residual compression and modest adhesion causing them to buckling driven blisters. In certain cases buckles with the shape of telephone cords are observed. A finite element model for quasi–static delamination growth is developed. Applying a Reissner–Mindlin shell kinematic for the film allows C ⁰− continuous shape functions. The traction vector at the film–substrate interface is obtained from the derivative of a cohesive free energy. Incorporation of loading and unloading conditions is considered for the irreversible process. The equilibrium state is computed iteratively in dependence of the compressive residual stresses. The computed telephone cord delaminations are stable asymmetric configurations whereas the symmetric configurations are unstable.     

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.     

Mechanical behavior and optimization of multidirectional laminate specimens under delamination by bending

Delamination process in the multidirectional laminates under bending loading conditions is often accompanied by excessive deformations ahead of the crack tip and non-linearities due to large displacements and transverse microcracks, which appear in the most strained plies especially for thin materials. Since linear elastic fracture mechanics cannot be directly used in order to characterize delamination, our objective is to highlight, experimentally and analytically, the delamination peculiarities on DCB specimens, then to optimize specimen thickness to the value, which makes it possible to avoid the appearance of transverse cracking before starting of delamination. The material used is E-glass/epoxy multidirectional laminates. The results of optimization obtained are in good agreement with the experimental data. __________ Translated from Problemy Prochnosti, No. 6, pp. 66–78, November–December, 2006.     

碳纤维增强复合材料螺旋铣孔切削力及加工质量研究

针对传统钻孔方法加工复合材料时易导致分层、撕裂等缺陷的问题,采用螺旋铣作为新的制孔技术,根据飞机装配现场的实际加工条件,构建以机器人为移动载体、螺旋铣孔终端执行器为加工单元、螺旋铣孔专用刀具为切削工具的加工系统,采用该加工系统对碳纤维增强复合材料(CFRP)螺旋铣孔关键工艺参数进行正交试验,并讨论了刀具主轴转速、每齿进给量和轴向切削深度等工艺参数对切削力的影响规律;通过对加工缺陷的监测,探讨了切削力与CFRP分层、撕裂等缺陷之间的关系;最后对工艺参数进行优化,经试验验证,优化后轴向切削力较优化前降低26%以上,孔入口及出口处均无撕裂、毛刺,加工质量最优。     

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.     

Tribological properties and high-speed drilling performance of Zr–C:H:Nx% coatings with different amounts of nitrogen addition

Zr–C:H:N _x% coatings with nitrogen additions ranging from 0 to 29 at.% are deposited on AISI M2 steel substrates and micro-drills using a closed field unbalanced magnetron (CFUBM) sputtering technique. The tribological properties of the coatings are tested against AISI 52100 steel balls under loads of 10 and 100 N, respectively, using an oscillating friction and wear tester. The drilling performance of the coated micro-drills is evaluated by performing high-speed through-hole drilling tests using printed circuit boards as a test material. The wear testing results reveal that the Zr–C:H:N_8% coating has excellent tribological properties, including a low wear depth, a low friction coefficient, and an extended lifetime. Meanwhile, the drilling tests reveal that the Zr–C:H:N_8% coating increases the tool life of the micro-drill by a factor of five compared to an uncoated micro-drill when used for the high-speed through-hole drilling of PCBs and yields a considerable improvement in the machining quality of the drilled hole.     

硬质合金台阶钻结构参数及钻削工艺参数对CFRP开孔性能的影响

基于VMC850B立式加工中心和UltraPAC超声C-扫描仪,搭建了碳纤维增强树脂基复合材料(CFRP)钻削试验平台,探讨了台阶钻结构参数及钻削工艺参数对CFRP钻削过程中的钻削轴向力和分层因子的影响。结果表明,钻削工艺参数对第一段钻削轴向力影响较大,台阶钻结构参数对第二段钻削轴向力的影响较大;分层因子的大小与第一段钻削轴向力和第二段钻削轴向力有关,当第一段和第二段直径比d/D0.5时,分层因子主要与第一段钻削轴向力有关;减小分层的优水平组合为第一段直径2.8mm,第二段锋角95°,主轴转速7000r/min,进给速度2.5mm/s。     

Phase composition and wear behavior of NiTi alloys

This study deals with the wear behavior of two NiTi shape memory alloys, one of them being martensitic, the other one austenitic at room temperature. Wear tests have been conducted with a disk-on-block geometry. The block was made of the NiTi alloy, whereas counterface disk materials were AISI M2 high-speed steel and a WC–Co hardmetal. From the evolution of the friction coefficient and temperature during the tests and from the characterization of the wear debris and traces, it has been possible to identify the main wear mechanisms. In the wear tests involving the M2 steel disk, both NiTi alloys display a transition, as a function of the applied load, from a mainly oxidation regime to a more complex situation, in which oxidation wear is accompanied by delamination of metallic alloy fragments. Higher wear rates of the shape memory alloys have been observed for the NiTi/WC–Co coupling. In this case, a transition from a mainly delamination wear to a regime featuring a mixture of delamination and oxidation wear has been observed.     

Synthesis and characterization of polyamide-6/graphite oxide nanocomposites

Polyamide-6/graphite oxide (PA6/GO) nanocomposites were synthesized using delamination/absorption method. The morphologies of the composites were characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). Both XRD and TEM showed that the GO sheets were completely exfoliated and distributed uniformly in PA6 matrix. Differential scanning calorimetry results revealed that the crystallization temperatures of the composites increased compared to that of pristine PA6, which was due to the heterogeneous nucleating effect of GO. However, the half-time of crystallization of the composites were evidently longer than that of pristine PA6, indicating an apparent decrease in the crystallization rate when GO was loaded into the polymer matrix. This was due to the constraining effect of layered GO on PA6 chains. The temperature of maximum decomposition rate was increased by 53 °C only by adding 5 wt% GO, and the maximum decomposition rate of the nanocomposites reduced greatly. The storage modulus (G′) and loss modulus (G″) curves shifted to higher modulus upon addition of 1–5 wt% of GO. With increasing GO loading, the shear viscosity of the nanocomposites gradually increased compared with pure PA6.     

In Situ Qualitative Inspection of Hole Exit Delamination at Bottom‐Ply during Drilling of Woven CFRP Epoxy Composite Laminates

Exploiting very high speed digital videography, an in situ examination of the hole exit delamination at the bottom‐most ply during drilling holes in the selected woven CFRP epoxy laminates is presented. At the beginning, a rotating elastic bulge of the carbon fibers at the bottom‐ply, which is just the impression of the protruding drill chisel edge, was always observed. Following the elastic bulging, a few, initial cracks along the weak fiber/matrix interfaces appeared. Thereafter, tensile failures in the carbon fibers were seen. The exact location of the initiation of these fiber failures specifically depends on the actual drill‐hole position with respect to the woven configuration of the bottom‐ply. A visual model for the weak interstitial or undulated regions at the bottom‐ply is also proposed in this paper, showing the undulating fibers, which are susceptible to mostly tensile failures under the drilling loads. During a sub‐completion drilling‐phase at the bottom‐ply, various cracks were seen to be propagating mostly via linear paths. Also, the exit delamination at the bottom‐ply during a sub‐completion drilling‐phase was always observed as to be divided into various small, independent localized contours—each of which propagated almost independently through within several individual warps/wefts during drill‐feed. Also, the shape of each such tiny contour within a single warp/weft was identified as elliptic, which is observed around an entire drill‐hole in unidirectional (UD) composites as reported in literature. It was also observed that the overhanging cantilever‐like fibers at the bottom‐ply are really difficult to cut, once their base‐location or their exit delamination contour reaches outside the hole nominal diameter. Moreover, by referring to some very basic cutting angle configurations for the orthogonal trimming of UD‐composites as found rarely in archival literature, an illustrative model diagram is also proposed for the drilling of the selected laminate material. This idea is also approximately validated via a few visual observations. The proposed visual model is generally an attempt in correlating the observed peripheral hole quality (delamination) with various instantaneous tool/fiber engagement configurations occurring across the entire drill‐hole periphery at the bottom‐ply, during the very last drilling‐phase.     

Effect of a novel sequential motion compaction process on the densification of multi-layer spray deposited 7090/SiCp composite

In the present study, a large dimension Al–10.15Zn–3.6Mg–1.8Cu–0.15Ni–0.3Zr/SiCp composite was synthesized by the multi-layer spray deposition process, then densities by a novel sequential motion compaction technique. The microstructures and mechanical properties of the multi-layer spray-deposited Al–10.15Zn–3.6Mg–1.8Cu–0.15Ni–0.3Zr/SiCp composite were studied by optical microscopy, scanning electron microscopy, and tensile tests before and after densities. The experimental results showed that sequential motion compaction technique can be used to fully density sample with large dimensions and difficult to further processing by the traditional techniques. This technique can greatly improve the microstructures and mechanical properties of the composite. The pores in the composite are elongated and closed through model pressing at the jointed effect of huge hydrostatic pressure and shearing stress. After pressed, SiC particles in the composite were broken and redistributed. Compared with the as-spray-deposited composite, the tensile properties of compaction processed composite have a great improvement not only in transverse direction but also in longitudinal direction. When the thickness reduction is about 40%, relative densities approach the theoretical density, and the actual relative density is 91.76%. The relative theoretical density is 93%.     

A review of mechanical drilling for composite laminates

Composite laminates (CFRP, GFRP, and fiber metal composite laminates) are attractive for many applications (such as aerospace and aircraft structural components) due to their superior properties. Usually, mechanical drilling operation is an important final machining process for components made of composite laminates. However, composite laminates are regarded as hard-to-machine materials, which results in low drilling efficiency and undesirable drilling-induced delamination. Therefore, it is desirable to improve the cost-effectiveness of currently-available drilling processes and to develop more advanced drilling processes for composite laminates. Such improvement and development will benefit from a comprehensive literature review on drilling of composite laminates. This review paper summarizes an up-to-date progress in mechanical drilling of composite laminates reported in the literature. It covers drilling operations (including conventional drilling, grinding drilling, vibration-assisted twist drilling, and high speed drilling), drill bit geometry and materials, drilling-induced delamination and its suppressing approaches, thrust force, and tool wear. It is intended to help readers to obtain a comprehensive view on mechanical drilling of composite laminates.     

Optimization of delamination factor in drilling GFR–polypropylene composites

Glass fiber-reinforced polypropylene composites often replace the conventional materials due to their special or unique mechanical properties. As the applications of these composites increase for a number of industries, drilling of these composites is inevitable for subsequent composite product manufacturing stage. In the drilling of composites, the thrust force is induced during the drilling operation; as a result, it causes damage. This damage is characterized by the delamination factor, which depends on the machining parameters such as speed of the spindle, feed rate, and drill diameter. The study on the delamination in the drilling of glass fiber-reinforced polypropylene is limited and has been carried out comprehensively. The effect of machining parameters on delamination in the drilling of glass fiber-strengthened polypropylene (GFR-PP) composites is studied through the Box–Bhenken design. Response surface method, along with the desirability analysis, is used for modeling and optimization of delamination factor in the drilling. The result proves that the models are effectively used to forecast the delamination in the drilling of GFR-PP composites. Also, the result indicates that the foremost issue that influences the delamination is the feed rate.     

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.     

Occurrence and propagation of delamination during the machining of carbon fibre reinforced plastics (CFRPs) - An experimental study

The machining of carbon fibre reinforced plastics (CFRPs) is often accompanied by delamination of the top layers of the machined edges. Such damage necessitates time-consuming and costly post-machining and in some cases leads to rejection of components. The work described in this paper systematically investigates the occurrence of delamination of the top layers during the machining of CFRP tape, with the focus being on the process of contour milling. The occurrence and propagation of delamination were studied by milling slots in unidirectional CFRP specimens having different fibre orientations and mainly analysing the slot tip. This allowed the key mechanisms to be clarified. The results show that delamination is highly dependent on the fibre orientation and the tool sharpness. The experiments allow derivation of a novel system for describing the occurrence and propagation of delamination during milling. Furthermore, the principles also apply for drilling. The results allow customisation of the machining procedure to reduce and in some cases totally avoid delamination, leading to a significant increase in the quality of components.     

Unilateral plastic delamination of a thin inclusion in the compressed layer under shear

The analytic solution of the problem of plastic delamination under shear of a plane thin rigid inclusion in the compressed layer is obtained by the methods of the theory of functions of complex variable. The inclusion is normal to the edges of the layer and located symmetrically about these edges. One side of the inclusion is in perfect contact with the medium and the other side suffers the action of friction forces caused by the compression of the layer. We determine both the length of the strips of plastic delamination as a function of the load and the load under which the inclusion becomes completely delaminated. Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 44, No. 6, pp. 47–52, November–December, 2008.     

Visible light photocatalytic properties of novel molybdenum treated carbon nanotube/titania composites

Two types of molybdenum–carbon nanotubes and molybdenum treated carbon nanotubes/titania composites were prepared using a sol–gel method. These composites were characterized comprehensively by the Brauer–Emett–Teller (BET) surface area, scanning electron microscopy (SEM), energy dispersive X-ray (EDX) analysis, X-ray diffraction (XRD), transmission electron microscopy (TEM) and UV-vis absorption spectroscopy. It was found that the photocatalytic degradation of a methylene blue solution could be attributed to the combined effects caused by the photo-degradation of titania, the electron assistance of carbon nanotube network, and the enhancement of molybdenum. The proposed redox mechanism of the photodegradation of methylene blue on Mo-CNT/TiO₂ composites is suggested.