Downloads

https://doi.org/10.53941/pcm.2025.100005
Basak, A. K., Pramanik, A. ., Shankar, S., Mohanraj, T., & Prakash, C. Effect of support and adhesive tape to reduce delamination of carbon fiber reinforced polymer during drilling. Progress in Composite Materials. 2025. doi: https://doi.org/10.53941/pcm.2025.100005
Volume 1, Issue 1, 2025
Copyright (c) 2025 by the authors.
Creative Commons License

This work is licensed under a Creative Commons Attribution 4.0 International License.

Article

Effect of Support and Adhesive Tape to Reduce Delamination of Carbon Fiber Reinforced Polymer during Drilling

Animesh Kumar Basak 1,2, Alokesh Pramanik 3,*, Subramaniam Shankar 4,5, Thangamuthu Mohanraj 6 and Chander Prakash 7

1 Adelaide Microscopy, The University of Adelaide, Adelaide, SA 5005, Australia

2 Centre for Research Impact & Outcome, Institute of Engineering and Technology, Chitkara University, Rajpura 140401, Punjab, India

3 School of Civil and Mechanical Engineering, Curtin University, Bentley, WA 6102, Australia

4 ProMind Research Academy, Erode 638012, Tamil Nadu, India

5 Nandha Engineering College, Erode 638052, Tamil Nadu, India

6 Department of Mechanical Engineering, Amrita School of Engineering, Amrita Vishwa Vidyapeetham,
Coimbatore 641112, Tamil Nadu, India

7 Centre for Research and Development, Chandigarh University, Mohali 140413, Punjab, India

* Correspondence: alokesh.pramanik@curtin.edu.au

Received: 13 November 2024; Revised: 22 January 2025;Accepted: 24 January 2025; Published: 10 February 2025

Abstract: Drilling carbon fibre reinforced polymers (CFRP) often causes several kinds of damage around the hole, such as delamination, which is considered one of the main issues that may occur when drilling the CFRP laminate. It significantly decreases the structural strength of the composite material and reduces its long-term performance. Using support plates and stacked materials as layers on the composite material has been identified as one of the main methods often used to reduce delamination. This research investigates the variations in delamination, fibre pull-out, thrust force, drilling torque, circularity and diameter error when drilling with and without adhesive tape layers. Furthermore, the research paper also explores the effect of varying drilling conditions and drill bit geometries on those output parameters. It has been revealed from the results that the proposed use of both adhesive tape layers and support plates can significantly limit delamination and fibre pull-out damages, thereby achieving a better-quality hole when drilling CFRP, as opposed to just using adhesive tape layers.

Keywords:

CFRP support drilling delamination carbon fibre reinforced polymer

References

  1. Chen, W. Some Experimental Investigation in the Drilling of CFRP Composite Laminates. Int. J. Mach. Tools Manuf. 1997, 37, 1097–1108.
  2. Ze, G.K.; Pramanik, A.; Basak, A.; et al. Challenges associated with drilling of carbon fiber reinforced polymer (CFRP) composites-A review. Compos. Part C Open Access 2023, 11, 100356.
  3. Basak, A.K.; Celis, J.-P.; Vardavoulias, M.; et al. Effect of nanostructuring and Al alloying on friction and wear behaviour of thermal sprayed WC–Co coatings. Surf. Coat. Technol. 2012, 206, 3508–3516.
  4. Basak, A.; Matteazzi, P.; Vardavoulias, M.; et al. Corrosion–wear behaviour of thermal sprayed nanostructured FeCu/WC–Co coatings. Wear 2006, 261, 1042–1050.
  5. Hocheng, H.; Tsao, C. The effect of pilot hole on delamination when core drill drilling composite materials. Int. J. Mach. Tools Manuf. 2006, 46, 1653–1661.
  6. Basak, A.; Celis, J.-P.; Vardavoulias, M.; et al. Coefficient of friction measured from nano-to macro-normal loads on plasma sprayed nanostructured cermet coatings. Metall. Mater. Trans. A 2014, 45, 1049–1056.
  7. Liu, D.; Tang, Y.; Cong, W. A review of mechanical drilling for composite laminates. Compos. Struct. 2012, 94, 1265–1279.
  8. Pramanik, A.; Basak, A.; Dong, Y.; et al. Joining of carbon fibre reinforced polymer (CFRP) composites and aluminium alloys—A review. Compos. Part A Appl. Sci. Manuf. 2017, 101, 1–29.
  9. Shunmugesh, K.; Kavan, P. Investigation and optimization of machining parameters in drilling of carbon fiber reinforced polymer (CFRP) composites. Pigment. Resin Technol. 2017, 46, 21–30.
  10. Jin, S.Y.; Pramanik, A.; Basak, A.; et al. Burr formation and its treatments—A review. Int. J. Adv. Manuf. Technol. 2020, 107, 2189–2210.
  11. Pramanik, A.; Basak, A.; Uddin, M.; et al. Burr formation during drilling of mild steel at different machining conditions. Mater. Manuf. Process. 2019, 34, 726–735.
  12. Pramanik, A.; Basak, A.K. Effects of Input Parameters on the Hole Quality During the Drilling of Al Metal Matrix Composites. Designs 2024, 8, 111.
  13. Wang, X.; Wang, L.J.; Tao, J.P. Investigation on thrust in vibration drilling of fiber-reinforced plastics. J. Mater. Process. Technol. 2024, 148, 239–244.
  14. Franck, G.; Frederic, D. New analytical model for delamination of CFRP during drilling. J. Mater. Process. Technol. 2017, 240, 332–343.
  15. Zitoune, R.; Krishnaraj, V.; Collombet, F. Study of drilling of composite material and aluminium stack. Compos. Struct. 2010, 92, 1246–1255.
  16. Pramanik, A.; Dixit, A.; Chattopadhyaya, S.; et al. Fatigue life of machined components. Adv. Manuf. 2017, 5, 59–76.
  17. Fernandes, M.; Cook, C. Drilling of carbon composites using a one shot drill bit. Part II: Empirical modeling of maximum thrust force. Int. J. Mach. Tools Manuf. 2006, 46, 76–79.
  18. Jain, S.; Yang, D.C. Effects of Feedrate and Chisel Edge on Delamination in Composites Drilling. J. Eng. Ind. 1993, 115, 398–405.
  19. Abrao, A.M.; Faria, P.E.; Rubio, J.C.C.; et al. Drilling of fiber reinforced plastics: A review. J. Mater. Process. Technol. 2007, 186, 1–7.
  20. Durão, L.M.P.; Tavares, J.M.R.; de Albuquerque, V.H.C.; et al. Damage evaluation of drilled carbon/epoxy laminates based on area assessment methods. Compos. Struct. 2013, 96, 576–583.
  21. Shyha, I.; Soo, S.L.; Aspinwall, D.K.; et al. Drilling of titanium/CFRP/aluminium stacks. Key Eng. Mater. 2010, 447, 624–633.
  22. Rimpault, X.; Chatelain, J.-F.; Klemberg-Sapieha, J.E.; et al. Burr height monitoring while drilling CFRP/titanium/aluminium stacks. Mech. Ind. 2017, 18, 114.
  23. Abrate, S.; Walton, D.A. Machining od composite materials. Part 1: Traditional methods. Compos. Manuf. 1992, 3, 75–83.
  24. Davim, J.P.; Reis, P. Drilling carbon fiber reinforced plastics manufactured by autoclave—Experimental and statistical study. Mater. Des. 2003, 24, 315–324.
  25. Tsao, C.; Hocheng, H.; Chen, Y. Delamination reduction in drilling composite materials by active backup force. CIRP Ann. 2012, 61, 91–94.
  26. Grilo, T.; Paulo, R.; Silva, C.; et al. Experimental delamination analyses of CFRPs using different drill geometries. Compos. Part B Eng. 2013, 45, 1344–1350.
  27. Gaitonde, V.; Karnik, S.; Rubio, J.C.; Correia, A.E.; Abrão, A.; Davim, J.P. A study aimed at minimizing delamination during drilling of CFRP composites. J. Compos. Mater. 2011, 45, 2359–2368.
  28. Capello, E. Workpiece damping and its effect on delamination damage in drilling thin composite laminates. J. Mater. Process. Technol. 2004, 148, 186–195.
  29. Hocheng, H.; Tsao, C.C. Effects of Special drill bits on drilling-induced delamination of composite materials. Int. J. Mach. Tools Manuf. 2006, 46, 1403–1416.
  30. Feito, N.; Diaz-Alvarez, J.; Diaz-Alvarez, A.; et al. Experimental Analysis of the Influence of Drill Point Angle and Wear on the Drilling of Woven CFRPs. Materials 2014, 7, 4258–4271.
  31. Chen, W.-C. Some experimental investigations in the drilling of carbon fiber-reinforced plastic (CFRP) composite laminates. Int. J. Mach. Tools Manuf. 1997, 37, 1097–1108.
  32. Mehta, V.; Dhull, U. Parametric Optimization in Drilling of Hemp-Glass Fiber/Polyester Resin Hybrid Composite Using Response Surface Methodology. IUP J. Mech. Eng. 2021, 14, 32–43.
  33. Ashrafi, S.A.; Sharif, S.; Farid, A.A.; et al. Performance evaluation of carbide tools in drilling CFRP-Al stacks. J. Compos. Mater. 2014, 48, 2071–2084.
  34. Davim, J.P.; Rubio, J.C.; Abrao, A. A novel approach based on digital image analysis to evaluate the delamination factor after drilling composite laminates. Compos. Sci. Technol. 2007, 67, 1939–1945.
  35. Nagarajan, V.; Sundaram, S.; Thyagarajan, K.; et al. Refined delamination factor failure characterization of composite wind turbine blade. Int. J. Damage Mech. 2012, 21, 1227–1244.
  36. Prakash, C.; Pramanik, A.; Basak, A.K.; et al. Investigating the efficacy of adhesive tape for drilling carbon fibre reinforced polymers. Materials 2021, 14, 1699.
  37. Abhishek, K.; Datta, S.; Mahapatra, S.S. Optimization of thrust, torque, entry, and exist delamination factor during drilling of CFRP composites. Int. J. Adv. Manuf. Technol. 2015, 76, 401–416.
  38. Durante, M.; Boccarusso, L.; De Fazio, D.; et al. Circular cutting strategy for drilling of carbon fiber-reinforced plastics (CFRPs). Mater. Manuf. Process. 2019, 34, 554–566.
  39. Ahmad, N.; Khan, S.A.; Raza, S.F. Influence of hole diameter, workpiece thickness, and tool surface condition on machinability of CFRP composites in orbital drilling: A case of workpiece rotation. Int. J. Adv. Manuf. Technol. 2019, 103, 2007–2015.