JOURNAL OF

COMPOSITE
Article M AT E R I A L S

Journal of Composite Materials

2021, Vol. 55(2) 235–249
Effects of cutting temperature and ! The Author(s) 2020
Article reuse guidelines:
process optimization in drilling sagepub.com/journals-permissions
DOI: 10.1177/0021998320947143
of GFRP composites journals.sagepub.com/home/jcm

A Tamer Erturk , Fahri Vatansever, Eser Yarar, E Asım Guven

and Tamer Sinmazcelik

Abstract
The present work deals with temperature effects and parametric optimization in the drilling of continuous glass fiber
reinforced epoxy composite. Drilling ability was examined operating a drilling system with different drill bits, feed rate,
and spindle speed parameters. The investigation was performed by changing the tool and composite interface. Drilling
experiments were carried out under the dry condition. Thrust force and drilling temperatures were measured using
dynamometer and thermal camera. Peel-up and push-out delamination were evaluated using an image analyzing tool.
Results show that the tribo-mechanical behavior of the drilling operation is affected at different levels by tool coating.
This behavior is related to the intrinsic friction properties of coating nature. Response surface methodology was used in
the evaluation of experiment results. The feed rate of 0.13 mm/rev, spindle speed of 2425 rpm and HSS-TiN drill bit are
found as an optimum drilling parameters and drill type.

Keywords
Polymer-matrix composites (PMCs), machining, delamination, response surface methodology (RSM)

Introduction
and push-out delamination, matrix cracking, fiber pull-
The prevalent usage of fiber-reinforced polymer com- out, fiber breakage and debonding.2,11–14 Thrust force,
posites (FRPs) as structural and functional materials torque, fiber/matrix interface strength affect delamina-
has been progressively replacing metals in automotive, tion damage as parametric factors on a drilling opera-
aerospace, aviation, military, and marine industries due tion.15 Delamination is the main damage type around
to their outstanding properties as high strength, light- the hole entry and exit affecting fatigue life and reduc-
weight, high stiffness, corrosion resistance with each ing the strength of composite material.1,16–18
passing day for the last few decades.1–6 FRPs are Delamination is also affected by assembly tolerance
formed by a proper combination of stiff and strong which may lead to part rejection especially in the aero-
fibers and polymer matrix phases. While the fibers act space industry.1,19 Different thermal properties of a
as load-bearing phase, the polymer matrix distributes matrix and fiber reinforcement may lead to another
loads to fibers and protect them from environmental problem. The thermal conductivity coefficients of the
damage.7,8 Although composites are generally manu- E-glass and epoxy are 1.3 and 0.21 W/m
C respectively.
factured in the finished form of a component, drilling Lower thermal conductivity and temperature transition
as the main machining operation is used for different prevent heat dissipation. The accumulated heat at a
purposes such as joining with rivets or bolts, producing
a cooling channel and a thermocouple assembly groove
in constructions.4,9 Non-homogeneous anisotropy Mechanical Engineering Department, Engineering Faculty, Kocaeli
highly abrasive reinforcement phase and inability to University, Turkey
plastically deformation result difficulties for machining
Corresponding author:
composite materials.3,5,8,10 There are reluctantly several A Tamer Erturk, Mechanical Engineering Department, Engineering Faculty,
defects associated with machining operations; material Kocaeli University, Izmit-Kocaeli, Turkey.
degradation due to thermal damage, spalling, peel-up Email: tamererturk@gmail.com
236 Journal of Composite Materials 55(2)

drilled hole destroys matrix stability and produces ther- focuses on how different drill bits and coatings affects
mal damages as burning of the matrix phase.4,20 It’s not temperature generated around a drilled hole. The main
recommended to use coolant during machining of com- motivation of this study is to find optimum drilling
posite materials because it is considered to be harmful parameters of GFRP material. For this purpose, the
to the physical and chemical characteristics of the effect of thrust force, torque, drill bit and drilling tem-
matrix phase.4,21 So, it is important to control the tem- perature were evaluated with different drilling param-
perature of the drilled hole without using coolant. This eters. Also, peel-up and push-out delamination factors
can be only achieved by optimization of the drilling were analyzed to compare the characteristics of differ-
parameters like feed rate, spindle speed, and drill ent drill bits and coatings with one another.
type. Thus, notable researchers conducted different
studies about the drilling of glass fiber reinforced poly-
Experimental procedure
mer composites (GFRPs) with using different drill
types.11,22–26 It is stated in many studies that feed rate Test material and tool properties
is the main factor that intimately affects the thrust
force, delamination and surface roughness where spin- A GFRP material consists of an epoxy matrix and con-
dle speed has only little impact in the drilling of GFRP tinuous glass fiber reinforcement with 0–90
orienta-
composites.11,27 Drilling of GFRP composites with tion commercially known as ISOVALVR TM was used.
HSS bit results in higher thrust force, surface rough- The weaving pattern of glass fibers can be seen in
ness and delamination factor according to carbide and Figure 1. This commercial composite type is extensively
coated drill bits.22–24 Similarly, a solid carbide drill bit used in those areas of electrical and fire insulating
exhibits better performance in terms of surface rough- applications where good machinability is required due
ness, torsional stability, during drilling of glass fiber to user’s high-quality assembly requirement. Samples
reinforced polypropylene composites.28 The critical were cut to 65x65 mm dimensions from 500x65 mm
delamination factor is exceeded during drilling of composite plate. The thickness of each sample is
GFRP after 30 holes with using HSS and HSS-TiN 20 mm. Mechanical properties and technical specifica-
coated tools, while it is 50 holes with using cemented tions are presented in Table 1.
tungsten carbide drill bit.29 Hole exit delamination is The samples were fixed to the dynamometer and the
reportedly avoidable by using a specialized tool that drilling machine utilizing a specially manufactured
provides dispersing and distributing the drilling clamp. The drilling operation was performed perpen-
loads.30 In terms of tool wear, after drilling GFRPs dicular to the lamination. Different drill types with dif-
of 1000 holes, comparative performance of drill bits ferent coatings were tested. The point angle, helix
results in thrust force and delamination increased dras- angle, and length dimensions are identical for all
tically when using HSS, whereas carbide tool occurred tools. In this study all used drills are twist drill. Only
a slight increase.25,26 cutting tool material (HSS or Carbide) or coating
In brief, mechanical fastening is the most suitable material are different.
and preferred method of joining for polymer compo- Tested tools, are mostly used drill bits in many
sites. Polymer composite parts with many holes assem- industrial operations, their properties can be seen in
ble to any structure using bolts and rivets. Fastener Table 2. HSS drill bits are frequently used to the dril-
bodies contact the holes and transfer the loads during ling of composites due to lower costs and high avail-
the static and dynamic loading. There is a serious dif- ability. The primary disadvantage of HSS bits their
ference between the hardness of fasteners and polymer inability to retain hardness at high temperatures.12,35
composites. As mentioned above, it is possible to Solid carbide tools are becoming common with their
damage the material, especially delamination, during higher hardness and wear resistance.12 Carbide drills
drilling on the polymer composite body. The existing provide high hardness and sufficient strength even in
damages gradually increase due to contact of the bolts/ high temperatures.35 Although the costs of carbide bits
rivets and maybe results in catastrophic errors.31 are becoming more reasonable, the prices are still much
Besides matrix degradation due to overheating during higher according to HSS bits. In addition to uncoated
drilling causes different mechanical failures as fibre tools, TiN and ZrN coated drill bits were also used in
pull-out, fiber breakage, matrix cracking, peel-up this study to compare the performance of coatings.
delamination, push-out delamination. Polymer compo- Tool materials with different coatings can withstand
sites must be drilled with the optimized parameters to higher temperatures in machining composites, and
avoid drilling-induced damage.31–33 they offer considerably higher wear resistance. The
As seen in given literature researchers mainly main function of drill bit coatings is isolating high tem-
focused on the effects of different tools on delamina- peratures especially present at the chip-tool interface.
tion. But there isn’t any comprehensive study that These coatings provide low thermal conductivities, low
Erturk et al. 237

friction coefficients and higher thermal resistance on allows to taking temperature measurements from inside
the tool. Particularly, ZrN coating is designed to with- of a drilled hole. Cutting force and torque data were
stand high thermal stress conditions for the machining recorded with a Kistler 9272 piezoelectric dynamome-
of abrasive materials in dry conditions.36 ter and a 5070 A model amplifier. The data acquisition
process is performed utilizing a program called
Experimental set up, optimization and validation DynoWare by Kistler Co. Drilling temperatures were
procedure recorded with a FLIR-A325sc model infrared camera.
The infrared camera placed 50 cm above the workpiece
The drilling operations have carried out using a Toss at an angle of 60
. Thus, the measurement can be per-
United TU5032B vertical drill machine. A schematic formed at a drilled hole surface from 5 mm below the
overview of the experimental set up is provided in upper surface. Temperatures of both drill bit and
Figure 1. A fixture was designed and machined which drilled hole surface were measured one second after
the drill bit comes out of the hole. Mean temperatures
of the selected areas calculated operating the FLIR
R&D software. A set of three holes were drilled for
each combination of input parameters under dry
machining condition. In Figure 1 three components
of cutting forces as Fx, Fy and Fz are shown. During
drilling, feeding occurs at Z-direction thus Fx and Fy
are practically equal to zero. Thus, Fz is evaluated as
the thrust force. Delamination at each hole entry and
exit have been evaluated with stereo microscope images
that are filtered with ImageJ analyzing tool, and
effected areas were calculated as peel-up and push-
out delamination factors. Moreover, chip formations
were characterized using thermal images obtained
from the infrared camera. The performance of GFRP
composite in drilling was considered and optimized by
conducting drilling experiments using four drill bits,
three spindle speeds, three feed rates compared with
Figure 1. The experimental setup and drilling direction of the a response surface methodology (RSM), as seen in
material. Table 3.
The experimental design was employed according to
the general full factorial method and the selected
Table 1. Mechanical properties and technical specifications of
parameters.37 RSM is a statistical method used to eval-
the test material.34
uate experimental results and express the effect of inde-
Density (g/cm3) 2.00 pendent variables on the responses
Flexural strength 23
C (MPa) 400
mathematically.38–40 The RSM was implemented for
Flexural strength 150
C (MPa) 200
the optimization and evaluation of experimental data
Compressive strength perpendicular 500
to laminations (MPa) with the effect of all the factors and their interactions.
Impact strength (kJ/m2) 50 The correctness of the model based on ANOVA was
Thermal conductivity (Wm-1 K-1) 0.27 revealed, and regression equations were acquired with
Thermal expansion (10-6 K-1) 20 RSM. Six models were established for thrust force,
torque, drill/material temperature, and peel-up/push-

Table 2. Properties of the drill bits.

Drilling bit HSS-R HSS-TiN Carbide Carbide-ZrN

Point angle 118
118
118
118

Total length (mm) 62 62 62 62
Helix length (mm) 26 26 26 26
Coating thickness (mm) – 1–4 – 4–5
238 Journal of Composite Materials 55(2)

Table 3. Selected factors and levels for the DoE model. Changes in thrust force during drilling with different
parameters are given in Figure 4. It is observed for
Factors Levels Values
0.3 mm/rev feed rate when the drill approaches the
Drill bit 4 HSS-R; HSS-TiN; end of the hole a sudden increase occurs in the thrust
Carbide; force curve of HSS-R. This is an indication of punching
Carbide-ZrN; operation without a chip removal process rather than
Spindle speed (rev/min) 3 535; 1720; 3030 drilling.48,49 This phenomenon can be seen in push-out
Feed rate (mm/rev) 3 0,1; 0,2; 0,3
delamination images in Figure 8 for HSS-R drill bit
with 0.2 and 0.3 mm/rev feed rate. Flute clogging,
out delamination assessment. Minitab 19 statistical defined as the adherence of the chips to the flutes also
occurred for HSS-R with 0.2 and 0.3 mm/rev feed rate.
software was used to evaluate the experimental results.
The increase in torque for this drill bit with increasing
While developing the model, feed rate and spindle
feed rate is an indication of this situation. Clogged
speed were defined as continuous, and drill bits as a
flutes of HSS-R drill bit failed to remove the chip
categorical factor. The relationship between the inde-
and attributed to punching.
pendent variables and the responses in RSM is defined
by a second-order polynomial model given below.
Thermal stability of the composite material
X
k X
k X
k1 X
k Thermal stability and thermal expansion properties are
y ¼ b0 þ bi xi þ bii x2 þ bij Xi Xj þ e (1) important to evaluate because the potential usage of
i¼1 i¼1 i¼1 j¼2
the composite is an insulator for high voltage applica-
tions. Dimensional changes due to the thermal effect to
Where y is predicted response, b0 is constant, bi, bii be encountered during machining have evaluated. The
and bij represent coefficients of linear, quadratic and thermal stability of the composite analyzed by using a
interaction terms respectively. While X shows the Discovery SDT 650 thermal analyzer. This operation
coded variables, e indicates the error.41,42 ANOVA carried out on a 10 mg sample at a temperature range
tables, contour and main effect plots were used in the of 30 – 850
C (with a 10
C/min heating rate) in a
analysis of the experimental results. ANOVA tables nitrogen atmosphere. Thermogravimetric analysis
and normal probability plots are given in supplemen- (TGA) is used for the thermal stability and decompo-
tary materials. Test results in the 95% confidence inter- sition evaluation of the composite at various temper-
val for the P values were considered at all variance atures. The TGA pattern as a function of temperature
analysis.10,37,43,44 is given in Figure 5. The mass loss takes place mostly
between 100 and 600
C. The composite shows good
thermal stability until approximately 300
C. Under
Results
300
C, a limited amount of weight change reveals the
Evaluation of thrust force and torque insulating character of the material can be maintained.
The cause of mass loss encountered up to this temper-
Thrust force is the force applied on the shear plane ature is generally attributed to the volatilization of
during drilling of a material.7 Thrust force contains degraded byproducts. TGA curve exhibits typically
two parts as resistance to feed and resistance to bend- three-stage weight loss behavior. The first decomposi-
ing.45 From here it is explicit that increasing feed rate tion stage starts at about 100
C with an accompanying
increases thrust force. However, the effect of spindle 5%wt loss. The second stage was then observed over
speed on thrust force is not clear.20,22,30,45–47 The size 300
C with approximately 30%wt loss and completed
of the delamination area is related to thrust force so stage as third at 500
C, where only 5%wt loss took
that measurement and analysis of it is a common place in the material. The higher mass-loss rate
approach.15 Figures 2 and 3 show the main effect and occurs at temperatures between 300 and 315
C. TGA
contour plots for the variation of thrust force and analysis shows that material has approximately 65%
torque concerning process parameters. While the inorganic reinforcing agent. The melting behavior,
thrust force and torque increase with increasing feed transitions with either endotherm or exotherm reac-
rate, increasing spindle speed doesn’t cause a remark- tions have been analyzed by the DSC in Figure 5.
able effect on thrust force and torque. Besides, the Initially, an exothermic reaction occurs from the
highest thrust force and torque values obtained when room temperature to 100
C. Further heat flow (exo-
using the HSS-R drill bit. Thrust force and torque therm and endotherm reaction) characterize recrystal-
values of carbide bits are close to each other where lization and melting. Changing heat flow values as a
HSS-TiN bit is a little bit higher than carbide bits. function of temperature can be provided in Figure 5.
Erturk et al. 239

Figure 2. Main effect plots for thrust force and torque.

Figure 3. Thrust force and torque graphs for different cutting parameters.

Also should be noted that this analysis was performed temperature of the drilled hole affects the surface qual-
under nitrogen atmosphere as a standard procedure. ity. Therefore, it is substantial to understand how dril-
These values allow comparison of the existing material ling temperatures are affected by the drilling
with other alternative materials tested in the same parameters.5,52 The amount of generated heat and con-
standards. But it should be noted that the thermal sequent temperature level of both drill bit and work-
values of the materials could be somewhat different piece are desired to know for drilling of composites.
at practical drilling process under air atmosphere. The generated heat by the friction between the tool
and workpiece dissipates by the workpiece, the tool,
chips, and the environment.21 Low thermal conductiv-
Temperature analyses during drilling operation ity of composite material contributes to the high-
The temperature of a cutting tool is a limiting factor of temperature generation by preventing heat dissipation.
machining composites.50 It is reported that tool life Temperatures of the hole surface and the drill bit are
increases with lower temperatures.51 Also, the affected by drilling conditions. An excessive
240 Journal of Composite Materials 55(2)

Figure 4. Comparison of thrust force graphs for different drill bits.

Figure 5. Thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) graphs.

temperature rise in the material detrimentally affects increment is type of drill bit. HSS-R drill bit causes the
hole quality,2 therefore, it is necessary to measure highest temperatures during drilling. This exposure
and analyze temperature during drilling of composites results in drilling defects discussed in the following sec-
to find and understand the main reasons of heat gen- tions. HSS-TiN drill bit causes much lower drilling
eration. The infrared radiation (IR) measuring method temperatures than HSS-R, which shows a temperature
gives information about the temperature of the work- decreasing effect of TiN coating. HSS-TiN drill bit out-
piece and the tool. It is possible to monitor moving performed even carbide drills in terms of temperature.
spindle or drill bit using IR cameras. The main advan- The TiN coating reduces material temperature about
tage of utilizing an IR camera is to detect temperature 60% and ZrN coating reduces material temperature
distribution around the drilling zone. IR cameras pro- about 45% compared with uncoated ones. It has
vide another advantage as measuring the average tem- been found that drilling with ZrN and TiN coated
perature of the selected area. IR cameras are tools allow to achieve lower temperature value com-
reported as being accurate and reliable.51 Figures 6 pared to an uncoated tool. It is well known that
and 7 show the main effects and contour plots for the heat transfer value of each drilling tool is consider-
drill and material temperature, respectively. From the ably higher than that of the composite material.
main effect plots, it is visualized that increasing spindle Composite material has a much lower heat transfer
speed or feed rate does not induce a significant temper- coefficient compared to the coated and uncoated
ature rise of drill bits. While material temperature tools so that generally lower material temperature
slightly increases with increasing spindle speed. From was detected compared to drill bit temperature, as
here, the main factor affecting the material temperature seen in Figure 6.
Erturk et al. 241

Figure 6. Main effect plots for drill and material temperature.

Figure 7. Drill and material temperature graphs for different cutting parameters.

Delamination and surface quality assessment delamination defect, there are controversial results in
The delamination size measurement and the delamina- the literature about how spindle speed affects.23,56
tion factor calculation of the drilled holes are common Figure 8 shows the images of peel-up and push-out
applications performed as indicators of the hole qual- delamination for informing researchers about the visi-
ity. Delamination of laminates occurs on the drill bit ble effects of different process parameters. The HSS-R
enter and exit stages as peel-up and push-out defects. drill bit causes wider hole entry and exit delamination
The cutting edges of a twist drill generate a peeling defects than other tools. Markedly, the push-out
force that separates the fibers of the top plies. The delamination is higher than the peel-up in general.
effect of this force occurs peel-up delamination There are several evaluation criteria for drilling-
defects.20,53,54 Approaching drill bit to the exit side of induced delamination in the literature. While the
the hole applied thrust force exceeds the inter-laminar one-dimensional delamination factor evaluates only
bonding strength. Therefore, drill bit pushes thin uncut damaged diameter, the two-dimensional factor analysis
laminates causes delamination.12,55 Although it is accu- offers a more precise evaluation of assessing the area.57
rately identified that an increase in thrust force induces 2 D delamination factor calculation method is used to
242 Journal of Composite Materials 55(2)

Figure 8. A set of selected micrographs for evaluating the peel-up and push-out delamination.

evaluate delamination in this study using the formula speed conflicted with trends of feed rate. It can be seen
given below: that spindle speed was slightly effect on push-out
  delamination, while increasing feed rate caused more
Adel  Anom delamination defects.
DF ¼ % (2)
Anom Figure 11 shows SEM micrographs of hole surface
drilled with 1720 rpm and 0.2 mm/rev. Fiber pull-out
Where Adel is the total damaged area with hole area and debonding defects and decomposition of the
and Anom is the nominal area of the drilled hole.1,57 matrix phase were detected in the drilled hole surface
Images were taken from the delamination defects using the HSS-R drill bit. It is stated in section 3.2 the
after drilling by a stereomicroscope and analyzed in first decomposition stage of the material starts at about
ImageJ software with a set of parameters adjusted 100
C with an accompanying 5%wt loss that obtained
such as brightness, threshold. Then, the affected area from TGA curve. Temperatures up to 160
C were
was measured with the help of the processing tool. obtained during drilling by HSS-R as given in
Using this data, 2 D delamination factor for both Figure 6. That is, with using HSS-R, drilling temper-
peel-up and push out delamination was calculated. atures reaches over 100
C causes matrix decomposi-
The main effect and contour plots for peel-up and tion which can be seen in Figure 11(a). Clogging of
push-out delamination factors are given in Figures 9 the drill flutes by using HSS-R drill bit was also
and 10, respectively. According to the main effect observed which is another indication of high process
plots, increasing the feed rate increases the delamina- temperature lead to decomposition of polymer materi-
tion factor. Moreover, increasing the spindle speed al. Low heat conductivity of matrix materials causes
caused an increase in peel-up and a decrease in push- generated heat to concentrate at the hole and contrib-
out delamination. The results showed that using the uted to surface damage. For the samples which were
HSS-R drill bit results in the highest delamination drilled with HSS-TiN and Carbide drill bits no damage
defect. According to Figure 10, an increment of spindle was detected for neither fiber phase nor matrix phase.
speed when using HSS-R causes more delamination Fiber breakages was observed for Carbide-ZrN drilled
formations. Although, the carbide drill bit provides sample as given in Figure 11(d). Such damages as fiber
better performance at higher spindle speeds for push- pull-out, debonding and fiber breakages are typical
out delamination, changing levels of the spindle speed damage modes of composite materials as stated in the
parameter didn’t affect peel-up delamination. Figure 9 literature.59–62
shows the main effect plots for peel up and push out During the process, drill bit encounters consecutive
delamination concerning machining parameters. The matrix and fiber phase, while forming force fluctuations
push-out delamination slightly decreased with the and consequent deterioration in chip formation. Chip
increasing feed rate from 0.1 to 0.2 mm/rev. It is not formation during drilling affects the drilled surface
consistent with the previous investigations. For quality. The formation of continuous chips results in
instance, the push-out delamination increased with better surface finish.63 Ribbon-like continuous chips
the increasing axial feed in the machining of CFRP obtained except when using the HSS-R drill bit as
holes.58 The trends of delamination defects with spindle seen in Figure 12. The HSS-R drill bit results
Erturk et al. 243

Figure 9. Main effect plots for delamination factor.

Figure 10. Peel-up and push-out delamination factor graphs for different cutting.

discontinuous and entanglement chip formations. It is indicates the effectiveness of the model. While R2 is
detected that higher spindle speeds caused shorter 79.69% for peel up delamination, the success of pre-
powder-like chip formations for all drill bits. Besides, dicting the experimental result of the regression equa-
as discussed before, clogging of the flutes took place in tions obtained for other responses is over 90%.
the use of the HSS-R drill bit with high spindle speeds. Multi-response optimization was used to obtain
optimum drilling parameters in the drilling of a mate-
Regression equations and multi-response rial.65–67 It is aimed to minimize all the answers exam-
ined for achieving sustainable quality and cost-effective
optimization
drilling. Table 5 shows the highest and lowest results
Table 4 presents empirical regression models developed for multi-responses obtained in experiments. This table
for mathematical prediction of operation responses also comprises desirability solutions obtained after
based on experimental results. R2 values used to the optimization. The desirability defines the
define the success of equations to predict experimental success of optimization for achieving desired results.
results are given in the same table.11,64 The high R2 The effectiveness of optimization increases as the
244 Journal of Composite Materials 55(2)

Figure 11. SEM micrographs of drilled hole surfaces for 1720 rpm and 0.2 mm/rev.

Figure 12. Chip formations for 535 rpm and 0.3 mm/rev conditions.

desirability value approaches 1. Table 6 shows the Discussion

optimum drilling parameters for glass fiber-
reinforced epoxy composites according to the results This type of composite has been required machining
of this study. processes for electrical insulating applications as a
structural material. The force-bearing structures must
Erturk et al. 245

Table 4. Empirical models of drilling operation responses.

Response Regression equations

Thrust force (N) 1.17 þ 401.0F þ 0.00684S þ 0.39D3 þ 0.35D4 – 8.03D1 þ 7.29D2 þ 4.5F2 – 0S2 – 0.02361F*S
R2¼99.86% – 198.16F*D3 – 188.85F*D4 þ 532.94F*D1 – 145.92F*D2 – 0.002704S*D3
– 0.003251S*D4 þ 0.008130S*D1 – 0.002175S*D2
Torque (N.cm) –0.194 þ 33.05F þ 0.000309S þ 0.540D3 – 0.144D4 –0.712D1 þ 0.316D2 þ 3.80F2 þ 0.S2
R2¼99.60% – 0.003074F*S – 19.502F*D3 – 16.259F*D4 þ 45.901F*D1 – 10.141F*D2 – 0.000276S*D3
– 0.000329S*D4 þ 0.000767S*D1 – 0.000162S*D2
Material Temperature (
C) 82.00 – 65.4F þ 0.00916S þ 9.27D3 – 12.24D4 þ 41.72D1 – 38.76D2 þ 187.0F2 – 0S2
R2¼98.66% – 0.00995F*S – 58.33F*D3 – 6.46F*D4 þ 14.45F*D1 þ 50.34F*D2 þ 0.000168S*D3
þ 0.002022S*D4 þ 0.001364S*D1 – 0.003553S*D2
Drill Bit Temperature (
C) 115.26 – 70.7F þ 0.00322S – 0.45D3 þ 3.22D4 þ 40.49D1 – 43.26D2 þ 220.8F2 þ 0S2
R2¼98.88% – 0.01613F*S – 52.00F*D3 – 52.63F*D4 þ 28.75F*D1 þ 75.87F*D2 þ 0.002909S*D3
þ 0.001177S*D4 þ 0.000592S*D1 – 0.004679S*D2
Peel-up Delamination 3.251 þ 1.66F þ 0.000339S – 1.396D3 þ 0.246D4 þ 0.742D1 þ 0.408D2 þ 6.9F2
R2¼79.69% – 0S2 þ 0.001481F*S þ 4.70F*D3 – 1.60F*D4 þ 1.17F*D1 – 4.27F*D2 – 0.000093S*D3
– 0.000049S*D4 þ 0.000043S*D1 þ 0.000100S*D2
Push-out Delamination 6.075 – 12.86F – 0.001564S – 0.133D3 – 1.741D4 – 0.260D1 þ 2.134D2 þ 32.31F2
R2¼94.69% þ 0S2 þ 0.001278F*S – 0.841F*D3 þ 3.310F*D4 þ 6.925F*D1 – 9.394F*D2
– 0.000347S*D3 þ 0.000065S*D4 þ 0.000537S*D1 – 0.000254S*D2
* F: Feed rate, S: Spindle Speed, D1: HSS R, D2: HSS TiN, D3: Carbide, D4: Carbide ZrN
** Using regression equations, related variable must be 1 and others must be 0.

Table 5. Parameters for multi-response optimization and desirability.

Response Goal Lower Upper Solution Desirability

Push-out delamination Minimum 2.04 8.18 3.82 0.93

Peel-up delamination Minimum 2.24 7.35 4.12 0.83
Drill temp. (
C) Minimum 63 165 70 1
Mat. temp. (
C) Minimum 45 145.13 50.33 0.95
Torque (N.cm) Minimum 1.26 25.1 3.40 0.91
Thrust force (N) Minimum 23.54 288 43.9 0.93

Table 6. Multiple responses prediction.

Feed rate (mm/rev) Spindle speed (rpm) Drill Composite desirability

0.126263 2425.15 HSS TiN 0.923333

be free from defects is a very basic engineering material and the drilling tool have different coefficients
approach. Moreover, in an isolated structure construc- of thermal expansion. The cutting temperature
tion, undesirable contact points can be found due to wouldn’t be higher than the decomposition tempera-
micro-voids arising from machining defects. Higher ture of the epoxy matrix, otherwise, it can cause the
surface quality is necessary for the efficiency of the disintegration of the material. Foreman et al. reported
insulation. Composite machining requires distinct that once the temperature was too high or even
tools and operating conditions. Optimum levels of exceeded the glass transition temperature of the resin.
thrust force, torque, drilling temperature must be deter- The yield strength and elastic modulus of epoxy resin
mined to maintain tolerance levels when using various decrease considerably with increasing temperature.68
machining tools. Because any aggressive force/temper- The elastic modulus of the resin would drastically
ature transients cause defects on the workpiece. decrease, and the physical performance was almost a
Dimensional accuracy during machining of composites failure.2 The thermal properties of the composite mate-
is desperately hard to predict since the composite rial were determined by TGA and DSC analysis.
246 Journal of Composite Materials 55(2)

Figure 13. Assessment of delamination according to thrust force and material temperature.

It was observed from the decomposition behavior that TiN drill bit according to the results of multiple
T5 temperature is nearly 110
C, losing 5%wt of the responses prediction.
material up to this temperature. The loss of the com- 2. The thrust force and torque increase with increasing
posite material increment reaches around 7%wt at feed rate. Increasing spindle speed doesn’t cause a
200
C. The material temperature was measured to remarkable effect on thrust force and torque. Thrust
rise up to 160
C when using the HSS-R drill bit. It force and torque values of carbide bits are close to
was designated that less delamination defect occurred each other whereas HSS-TiN bit gives a little bit
parallel to this for the carbide-ZrN drill bit. Therefore, higher, and the HSS-R drill bit gives the highest
it is critical to consider Figures 7 and 13 for determin- result.
ing drill bit type and process parameters. It is difficult 3. It is detected when the HSS-R drill approaches the
to obtain smooth surfaces after machining because the end of the hole a sudden increase occurs in the thrust
fiber reinforcement. Thus, the drill hole has burr sur- force. Because of flute clogging of HSS-R drill bit
faces because of non-consistent chip deformation. failed to remove the chip and attributed to
Delamination is the most important defect cause of a punching.
decline in endurance and reduces structural integrity. 4. While material temperature slightly increases with
Mechanical and insulating performance of the material increasing spindle speed. Increasing spindle speed
is therefore responsible for the delamination zone. or feed rate does not induce a significant tempera-
Fiber pull-out, debonding, decomposition of the ture rise of drill bits. HSS-R drill bit causes the
matrix phase due to thermal damage and rarely seen highest temperatures that results in drilling defects.
fiber breakages are the other damage modes of the HSS-TiN drill bit outperformed even carbide drills
composite material. The average results of this study in terms of temperature.
visualized according to different parameters and drill 5. It is critical to consider the parametric analysis for
bits in Figure 13. This analysis provides an assessment determining drill bit type and process parameters.
of delamination concerning thrust force and material 6. Material temperature is a more effective factor for
temperature. It is figured out that an increment of push-out delamination defects as obtained from
thrust force causes increasing defects as peel-up and parametric analysis.
push-out delamination. Besides, material temperature
is a more effective factor for push-out delamination
defects. Highlights
• The effects of process parameters on the drilling per-
Conclusion formances are investigated in this study.
The glass fiber reinforced thermoplastic epoxy compos- • This study provides an assessment of delamination
ite is taken into consideration for studying the drilling concerning thrust force and temperature.
characteristics using different drill bits by varying the • Temperatures of the hole surface and the drill bit are
process parameters. The results of this study can be affected by drilling conditions.
listed as follows: • The main factor affecting the material temperature
increment is drill bit type.
1. The optimum drilling parameters are feed rate 0.13 • Thrust force/torque increases with increasing feed
mm/rev, spindle speed 2425 rpm with using HSS- rate, whereas spindle speed doesn’t cause.
Erturk et al. 247

Declaration of Conflicting Interests composites using different drills. Measurement 2020;

149: 106973.
The author(s) declared no potential conflicts of interest with
12. Nassar MMA, Arunachalam R and Alzebdeh KI.
respect to the research, authorship, and/or publication of this
Machinability of natural fiber reinforced composites: a
article. review. Int J Adv Manuf Technol 2017; 88: 2985–3004.
13. Alberdi A, Artaza T, Suárez A, et al. An experimental
Funding study on abrasive waterjet cutting of CFRP/Ti6Al4V
The author(s) disclosed receipt of the following financial sup- stacks for drilling operations. Int J Adv Manuf Technol
port for the research, authorship, and/or publication of this 2016; 86: 691–704.
14. Haddad M, Zitoune R, Eyma F, et al. Influence of
article: The authors thank the Advanced Material
machining process and machining induced surface rough-
Laboratory at Kocaeli University Technopark for supporting
ness on mechanical properties of continuous fiber com-
our experiments. posites. Exp Mech 2015; 55: 519–528.
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ORCID iD delamination-free drilling of composite materials.
A Tamer Erturk https://orcid.org/0000-0002-2901-5703 J Mater Process Technol 2005; 167: 251–264.
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