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Available online at www.sciencedirect.com

www.jmrt.com.br

Review Article

Drilling on fiber reinforced polymer/nanopolymer

composite laminates: a review

Kishore Kumar Panchagnula a,b,∗ , Kuppan Palaniyandi a

a School of Mechanical Engineering, VIT University, Vellore, India
b Department of Mechanical Engineering, Vignana Bharathi Institute of Technology, Aushapur, Hyderabad, India

a r t i c l e i n f o a b s t r a c t

Available online xxx Among various machining operations, drilling is the most commonly employed machining
operation for polymer composite laminates owing to the need for joining structures. Work
Keywords: with commercial composites has identified numerous parameters during the drilling oper-
Drilling ation that can influence the drilling factors and the material damage. The present paper
FRP laminates gives a precise review of drilling on current state of fiber reinforced polymer as well as
Nanopolymer composite laminates nanopolymer composite laminates. Specifically, the influence of machining parameters,
Cutting forces tool geometry, tool materials and tool types on the cutting force generation and delami-
Delamination nation mechanisms. Based on the comprehensive literature survey from the past few years,
it is noticed that limited research has been made and published concerning to nanopolymer
composite drilling and has led to a partial understanding of the cutting mechanics activated
in machining/drilling. Some key contributions such as experimental and numerical studies
are urgently demanded to address accurately various projections in drilling of nano-particle
reinforced FRP composite laminates.
© 2017 Brazilian Metallurgical, Materials and Mining Association. Published by Elsevier
Editora Ltda. This is an open access article under the CC BY-NC-ND license (http://
creativecommons.org/licenses/by-nc-nd/4.0/).

goods, marine and oil industries, due to their special physical

1. Introduction
Composite materials are made-up of least two distinct
intended materials which together improve product perfor-
mance and lower manufacturing cost [1]. Many materials,
continuously designated by other terms are also consid-
ered composites including clad, coated metal tools, etc. [2].
Nowadays, FRP composite laminates are the materials of
option for many engineering applications; namely, automo-
tive parts, sporting goods, aerospace components, consumer
and mechanical properties [3].
The basic initiative behind the learning of FRP composite
laminates mainly comprise Glass Fiber Reinforced Polymer
(GFRP) composite laminates, Carbon Fiber Reinforced Poly-
mer (CFRP) composite laminates and nanopolymer composite
laminates and their applications are based on the possibility
of using materials with definite characteristics and ultimate
properties that are not found in any of the raw materials [4].
The most recent commercial aircraft designs propose
a reduction in weight about 50% by replacing the primary

∗
Corresponding author.
E-mail: kishorephd0208@gmail.com (K.K. Panchagnula).
http://dx.doi.org/10.1016/j.jmrt.2017.06.003
2238-7854/© 2017 Brazilian Metallurgical, Materials and Mining Association. Published by Elsevier Editora Ltda. This is an open access
article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Please cite this article in press as: Panchagnula KK, Palaniyandi K. Drilling on fiber reinforced polymer/nanopolymer composite laminates: a
review. J Mater Res Technol. 2017. http://dx.doi.org/10.1016/j.jmrt.2017.06.003
JMRTEC-274; No. of Pages 10
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structural components with fabricated nanopolymer compos-
ites. Using light weight and elevated strength composites are
essential in order to achieve the reduced fuel consumption
and better passenger comfort goals of these future com-
mercial aircraft design innovations [5]. In generally, all the
composite materials will undergo some machining processes
in their fabrication procedure or its specific engineering appli-
cation. With the concern of the current industry, drilling is the
most frequently used hole making operation for assembly of
structures or components. Various industries; such as auto-
motive, aerospace, marine and oil industries, have already
started the utilization of nanocomposites in their structures.
The composite damage called delamination is an inter-
ply failure phenomenon induced by drilling, which is a very
serious problem and has been recognized as an unexpected
major damage when drilling composite laminates [6]. Due to
the non-homogeneity, multi-phase structure and anisotropic
nature of the composites lead to an inter-ply failure during
drilling [7]. With that reason, about 60% of the drilled holes on
composites are rejected at the initial stage only [8].
In addition to delamination, sub-surface deformation is
another important drilling induced damage while composite
machining. Interfacial debonding, matrix deformation, fiber
pullouts, matrix crazing, cracking, hole shrinkage and spalling
are few examples of sub-surface deformations [9,10]. So, in
order to improve the product performance and structural
integrity of machined holes, the material defects such as sub-
surface deformation and delamination has to be trim-down
by proper selection of cutting parameters, tool geometries,
tool types and cutting conditions [11,12]. Nevertheless, the
structural integrity is also strongly depending on fiber matrix
interfacial interactions, fiber orientations, cutting directions
and tool wear.
Zhang et al. [13] have investigated the spalling, fuzzing exit
sub-surface deformation defects during drilling of unidirect-
ional as well as multi-directional CFRP laminates with HSS
twist drill. Spalling and fuzzing are considered as the major
exit damage mechanisms during drilling of FRP composite
laminates and these damages increase with an increase in
feed rate and decrease in spindle speed. Spalling at hole exit
is usually a severe damage and it is bigger for UD-CFRP lami-
nate as compared to multi-directional CFRP laminate under
the same drilling conditions. Khashaba et al. [14] reported
that catastrophic shear failure of the composite layers has
been done due to the higher feed rates and cutting temper-
atures resulting poor surface integrity, lower bearing strength
of machined holes while GFRP composite drilling. Heisel
et al. [15] investigated the influence of point angle, cutting
parameters on cutting forces and drill hole quality i.e. fry-
ing, burr formation and delamination have been investigated
while drilling of CFRP laminates. The increase in point angle
increases cutting temperature resulting frying of epoxy matrix
with poor quality drilled hole and severe burr formation.
Brinksmeier et al. [16] tried three (Alu-
minum/CFRP/Titanium) different materials to investigate
the surface quality of boreholes after orbital and conventional
drilling processes. Compared to the conventional drilling
process, orbital drilling gives the finest borehole surfaces with
tiny matrix cracks and without fiber breakage under lower
cutting temperatures and large cutting speeds. Arul et al. [17]
Please cite this article in press as: Panchagnula KK, Palaniyandi K. Drilling on fiber reinforced polymer/nanopolymer composite laminates: a
review. J Mater Res Technol. 2017. http://dx.doi.org/10.1016/j.jmrt.2017.06.003
have utilized acoustic emission technique to improve the
quality and surface integrity of the machined hole during
drilling on woven glass fabric/epoxy composite laminates.
The effect of cutting parameters on axial force, flank wear
and their influence on the hole shrinkage was monitored and
correlated with AE parameters. Abhishek et al. [18] employed
PCA-fuzzy integrated with Taguchi’s philosophy technique to
optimize the cutting parameters for trim down the delam-
ination, sub-surface damage defects while drilling of CFRP
composites. Eneyew and Ramulu [19] have studied the effect
of cutting parameters, cutting direction and fiber orientation
on the drilled hole surface quality in the UD-CFRP composite
laminate. The lower value of thrust force was identified at a
rotational angle of 135◦ and 315◦ , fiber pullouts are observed
at two cutting regions where the cutting direction and fiber
orientation interface angle is from 135◦ to 175◦ and 315◦ to
355◦ . The examined sub-surface damages i.e. delamination,
surface roughness, fiber pull outs are captured through
SEM.
Generally, when the drill tool is commerce with the FRP
laminate, the drill chisel edge generates a nominal thrust force
in the axial direction and subsequently initiates the surface
deformation due to the frictional rubbing action of tool and
work-piece [20,21]. This deformation can remain the same
upto the last two piles of composite laminates and increases
drastically for further drill extent due to the smaller uncut
chip thickness, lower resistance to deformation and stiffness.
At this instant, the exit side of the laminate undergoes severe
damage of matrix and initiation of crack propagation result-
ing poor surface integrity [22,23]. Tool-work piece Tribological
interactions are also reasons for sub-surface deformation of
the composites and these thermo-mechanical mechanisms
can be reported in the form of tool wear [24]. Abrasion is con-
sidered as chief tool wear mechanism during drilling on FRP
as well as nano composite laminates and it can be occurred
mainly on rake and flank face of the tool cutting edge causing
severe abrasive wear on the flank face resulting poor struc-
tural integrity and long-term performance deterioration of the
machined surface [25]. Inoue et al. [26] inspected the effect of
tool wear on the sub-surface deformation in drilling of small
diameter holes of GFRP composites. Based on experimental
results, it was concluded that higher flank wear occurs at lower
feed rates and larger cutting speeds.
So, in order to eradicate the defects induced during
drilling on conventional composites such as GFRP and CFRP,
these composites are modified with secondary reinforcements
called nano-fillers; namely carbon nano-fibers (CNFs), carbon
nanotubes (CNTs), polyamide 6, Polypropylene-Silicon for the
property enhancement of composite laminates. A typical lay-
out of classification of composite materials is shown in Fig. 1.
Abrao et al. [27] have made an extensive literature on
drilling of FRP composites. Aspects such as tool geometry,
machining parameters and their influence on thrust force,
torque and delamination are examined in the review. Liu et al.
[4] provided a review on mechanical drilling of composite
materials such as FRP (CFRP, GFRP) as well as fiber metal com-
posite (FML) laminates. This review paper also encloses with
grinding drilling, Vibration-assisted twist drilling (VATD) and
high speed drilling (HSD) operations of both FRP and FML com-
posites.
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Composite materials
Fiber-reubfirced composites
Random orientation
Single layer composites
Continuous fibers
Unidirectional reinforcement Bidirectional reinforcement
Fig. 1 – A typical classification of composite materials.
Starost and Njuguna [28] have prepared a report on
the effect of mechanical drilling on nanocomposites lami-
nates. The effect and influence of various drilling param-
eters on delamination and nano-sized particles have been
analyzed. Davis et al. [29] reported that amino func-
tionalized single-walled CNTs/CFRPs and fluorine doped
single-walled CNTs/CFRP nanocomposite laminates exhibit
good improvement in tensile strength, stiffness and fatigue
durability compared to non-functionalized composites under
tension–tension and tension–compression loadings. The
multi-walled CNTs/CFRP composite laminates cured by
microwave process was prepared to prevent delamination
and drilling ablation and have been compared against
normal conventional thermal cured composite without MWC-
NTs [30]. The fiber reinforced composite laminates thermal
conductivity has been increased drastically with the addi-
tion of nano-filler/micro-filler; namely, MWCNTs, DWCNTs
[31].
The present work provides a detailed review of drilling
on FRP as well as nanopolymer reinforced composite lam-
inates. A huge research work has been done on drilling of
conventional FRP composites, but there is a need to con-
tinue research in the field of nanocomposite drilling especially
nano-particle (CNF/CNT) reinforced FRP composites where
there are limited publications. As specified, nanocomposites
are newly introduced materials in the commercial industry as
well as unlike properties due to their non-homogeneity struc-
ture; they can perform in a different way in drilling. In addition
to that the identification of effects of cutting parameters, tool
geometry, tool types and tool materials on the thrust force,
torque and delamination in drilling of nanopolymer compos-
ites is compulsory for better understanding of machinability.
2. Drilling operations
2.1. Drilling on conventional FRP composites
There are several types of drilling operations on composite
laminates but conventional drilling is the most frequently
Please cite this article in press as: Panchagnula KK, Palaniyandi K. Drilling on fiber reinforced polymer/nanopolymer composite laminates: a
review. J Mater Res Technol. 2017. http://dx.doi.org/10.1016/j.jmrt.2017.06.003
3
Particle-reubfirced composites
Preferred orientation
Multi layer composites
Laminates Hybrids
Discontinuous fibers
Random orientation Preferred orientation
used drilling operation and other operations like vibration
assisted drilling, high speed drilling are also used and provides
superior quality of drilled holes as well as high efficiency [4].
The research on development of mechanical drilling on com-
posite materials focuses mainly on drilling mechanics, drill
tool geometry and material, tool types, delamination mecha-
nisms and its preventing approaches, cutting force, and tool
wear, etc. The composite damage called delamination is an
inter-ply failure phenomenon induced by drilling, which is a
very serious problem and has been recognized as an unex-
pected major damage when drilling composite laminates. The
SEM images of delamination of GFRP and CFRP were as shown
in Fig. 2.
Based on the review on experimental analysis, it is found
that the input parameters such as cutting speed, feed and
point angle of twist drill, tool types, tool materials, type of
drilling operation directly affect the drilling induced delam-
ination on FRP composites. The following observations are
noticed from literature survey on drilling in composite lam-
inates [32–35]:
Delamination at exit is more severe than at entry.
Delamination tendency increased with the increase of twist
drill point angle.
Special drill bits (straight-flute drill bit, brad point drill bit
and step drill bit) with larger feed rate shows without delam-
ination compared with the twist drill bit.
Carbide coated and diamond coated tools give up better
results in terms of tool wear and tool life during drilling on
composites.
Generally, the minimum delamination defect on composite
materials occurs at low feed rates with high cutting speeds.
In addition to the cutting parameters, tool geometry, tool
types, etc., the work piece constituents, laminate orienta-
tion (0◦ /0◦ /0◦ /0◦ , 45◦ /45◦ /45◦ /45◦ , 0◦ /45◦ /0◦ /45◦ , 45◦ /0◦ /45◦ /0◦ ,
0◦ /0◦ /45◦ /45◦ and 45◦ /45◦ /0◦ /0◦ ) also effect the delamination
in drilling of composites [36,37]. Table 1 shows the detailed
range of cutting conditions during drilling on CFRP and GFRP
composite laminates.
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Table 1 – Available literature in drilling on FRP composite laminates.

Material Ply/sheet References Drilling conditions

UD-ply Park et al. [69]; Bhatnagar et al. [70]; Lin and Chen Spindle speed: 800–1600 rpm
CFRP laminates
[71]; Chen [72]; Piquet et al. [73]. Feed rate: 0.05–0.20 mm/rev
Diameter (d): 4–6 mm
Point angle (h): 90–118◦
Laminate thickness (T): 2–3 mm
Woven ply Gaitonde et al. [74]; Karnik et al. [75]; Faraz et al. [76]; Spindle speed: 60–600 rpm
Shyha et al. [77]; Lazar and Xirouchakis [63]. Feed rate: 0.01–0.06 mm/rev
Diameter (d): 6–9 mm
Point angle (h): 85–130◦
Laminate thickness (T): 2–3 mm

UD-ply Mathew et al. [78]; Ramkumar et al. [79,80]; Capello Spindle speed: 375–1500 rpm
GFRP laminates
[81]; Rao et al. [82]; Mkaddem et al. [83]; Lasri et al. Feed rate: 0.075–0.3 mm/rev
[84]; Diameter (d): 6 mm
Kilickap [85]. Point angle (h): 90–118◦
Laminate thickness (T): 2–4 mm
Woven ply Khashaba et al. [86,87]; Velayudham et al. [88,89]; Spindle speed: 60–500 rpm
Arul et al. [90,91]; Rubio et al. [92]; Isik and Ekici [10] Feed rate: 0.05–0.45 mm/rev
Diameter (d): 6–10 mm
Point angle (h): 90–118◦
Laminate thickness (T): 6–9 mm

2.2. Drilling on nanopolymer composites
As polymer nanocomposites are comparatively newly rec-
ognized materials, very few studies have been produced on
the drilling on nanocomposites. As of the existing literature,
limited details are available on the development of nanocom-
posites, property evaluation, drilling delamination, processing
technologies and thermal damage in polymer nanocompos-
ites drilling [38–42].
Li et al. [30] have used microwave curing process to
prevent delamination and drilling ablation in drilling of car-
bon nanotube/carbon fiber reinforced epoxy composites. The
revealed experimental results had given decreased drilling
induced delamination of microwave cured nanocomposites
and increased interlaminar fracture toughness upto 66% com-
pared to normal cured composites. Baker et al. [43] have
studied the drill tool coatings to minimize the wear resis-
tance during drilling on nanocomposites. Paul et al. [44] have
employed acoustic emission technique for on-line monitoring
of drilling induced delamination during drilling on CNF rein-
forced nanocomposites laminates. The availed literature on
drilling of nanocomposite laminates and its drilling conditions
are given in Table 2.
3. Need for monitoring drilling on
composites
Commercial FRP composite materials have definite character-
istics which impel their machining behavior. Consequently,
the mechanisms involved while drilling composite mate-
rials are specifically different from those observed when
drilling homogeneous materials such as metals. Work with
commercial composites has recognized numerous param-
eters during the drilling operation that can influence the
drilling factors and the material damage. Damage particu-
larly related to drilling on composites primarily investigates
delamination mechanisms, as this is the foremost and most
important cause of component rejection as a result restricts
the use of composite laminates for structural applications.
Other defects induced by drilling comprises peel up and push
out delaminations, circularity error, tiny cracks are likely to
occur.
Drilling induced delamination was also caused by drill
tool wear when drilling on FRP composites. The experimen-
tal results show that the critical thrust force is increased
with growing wear which in turns increases the delamination.
Drilling delamination of worn twist drill for lower feed rate is
very low compared to sharp drills and these results are agreed
with industrial experience [10].
4. Drilling factors
The input process parameters like cutting parameters, tool
geometries, tool types and tool materials show the effect on
thrust force, torque, tool wear, delamination, surface rough-
ness etc. which are called output process parameters. So,
it is necessary to select the proper process parameters for
obtaining the best performance on the drilling operation
i.e. best hole quality, which represents minimum damage of
the machined components and satisfactory machined sur-
face. Fig. 3 shows the schematic representation of drilling on
composite laminates for the better understanding of drilling
studies.
5. Cutting parameters
The cutting parameters such as cutting velocity and feed
rate, tool geometry, tool types and tool materials have shown
greater effect on the thrust force, torque and delamination
while drilling conventional as well as nanopolymer composite
laminates.

Please cite this article in press as: Panchagnula KK, Palaniyandi K. Drilling on fiber reinforced polymer/nanopolymer composite laminates: a
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Table 2 – Drilling operations typically employed for nanopolymer composite laminates in literature.
Material References Remarks

CFRP/CNF, hybrid carbon/glass
fiber, polypropylene/CNT, PA6/CNT,
polypropylene-silicon, Si3 N4 /epoxy
Irfan et al. [68]; Sophia Sachse et al. [60];
Bello et al. [49]; Paul et al. [44]; Tan et al.
[50]; Li et al. [30]; Starost and Njuguna
[28]; Gowda et al. [53]; Baker et al. [43]
Spindle speed <1500 rpm and feed rate
<0.1 mm/min.
Adjacent to the uncoated HSS drill, other
coated drills such as carbide coated, CBN
coated, diamond coated and diamond-like
coated drills are also used in drilling of
nanopolymer composites.
A combination of high spindle speed and low
feed rate reduces the delamination and
circularity error.

5.1. Effect of cutting parameters on thrust force,

a torque and delamination

The drilling parameters such as spindle speed and feed

rate highly influence the cutting forces and delamination in
drilling of FRP as well as nanocomposites laminates. The
cutting forces decrease with the higher cutting speed and
Delamination increase with the escalating feed rate, drill size and fiber
volume fractions. In drilling of carbon/epoxy composites the
torque, thrust force and delamination factor depends directly
on the feed rate and tool geometry [21,24].
Phadnis et al. [45] experimental study reported that low
50
feed rates (<1500 mm/min) and high cutting speeds (>600 rpm)
are the best cutting parameters for drilling on carbon/epoxy
laminates. An exceeded experiment have been done on FRP
drilling by varying the machining conditions to investigate
the correlations between cutting forces, drilling delamina-
tion, tool wear, temperature and hole quality. In addition
to the cutting parameters, the cutting edge of the drill tool
has also generates some local feed cutting forces which indi-
rectly influences the hole exit delamination on FRP composites
Deep valley
Delamination [46,47]. Palanikumar et al. [48] experimental and analytical
area, Adel results indicated that the low feed rate and drill diameter
leads to increase the thrust force, whereas the increase in the
spindle speed does not show any disparity.
b Bello et al. [49] have conducted a series of drilling experi-
ments on advanced CNT hybrid composites at a spindle speed
range of 725–1325 rpm for optimum cutting conditions. The
spindle speed of 1015 rpm gives the lower thrust force and
Dmax torque values. Tan et al. [50] have done some drilling exper-
iments on hybrid carbon/glass nanocomposite laminates to
optimize the cutting parameters. The experimental results
and statistical analysis reveal that the second order regression
Dnom model is suitable for prediction of drilling induced delami-
nation and surface roughness responses. Paul et al. [44] have
selected the cutting parameters range of 500–1500 rpm in spin-
dle speed and 0.02–0.08 mm/rev in feed rate for minimum
drilling induced delamination and surface roughness during
drilling on CNF reinforced CFRP nanocomposite laminates.
Specifically, the lower feed rate (0.02 mm/rev) and higher spin-
dle speed (1500 rpm) gives the better thrust force and torque
values.
Generally, statistical techniques such as ANOVA, regression
Fig. 2 – SEM images of delamination (a) intersection image analysis etc. were used to establish an empirical relation-
of GFRP; and (b) surface image of CFRP [4]. ship between the drilling parameters (feed rate, spindle
speed, drill diameter and fiber volume fraction) and cutting

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Drilling of composites

Drilling of Drilling of Drilling of

conventional multi material nanopolymer
composites composites composites

Machining parameters: Tool parameters:

1. Feed 1. Tool geometry
2. Spindle speed 2. Tool material
3. Tool type

Monitoring parameters

Online parameters: Offline parameters:

1. Thrust force 1. Delamination factor
2. Torque 2. Circularity
3. Surface roughness
4. Tool wear

Fig. 3 – The schematic representation of drilling of composite materials.

forces in drilling of FRP composites. Optimizing the machin-
ability characteristics like feed rate and spindle speed on
nanoploymer composite drilling was an essential task, to
suppress the drilling defects, thrust force, surface rough-
ness and tool life [51,52]. So, the cutting parameters such
as cutting speed and feed are deeply influences the thrust
force, torque and delamination during drilling on conven-
tional/nanopolymer composite laminates. Gowda et al. [53]
have employed Taguchi’s orthogonal array technique to
optimize the cutting parameters in drilling on Si3 N4 nanocom-
posite laminates, by varying input parameters like %volume of
Si3 N4 (0, 6, 10), speed (360, 490,680 rpm) and feed rate (0.095,
0.19, 0.285 mm/rev). The output response variables like circu-
larity error, surface roughness were tabulated through ANOVA
table.
angle of a drill tool highly affects the machining forces and drill
whole quality (delamination, fraying, and burr formation) on
drilling of CFRP composites. The increasing of point angles
(155◦ , 175◦ , 178◦ and 185◦ ) increases the feed force, drilling
torque and delamination factor also [15]. Fig. 4 shows the
delamination factor value for different drill tool geometries.
Guo et al. [9] have studied carbide twist drills of differ-
ent diameters (3–8 mm), varying web thicknesses (0.5, 0.55,
0.7, and 1.1 mm) and preferred drill tool angles that provides
the optimal cutting parameters and high-quality drilled holes
1.25
1.2
Fd - de lamination factor

Therefore, in order to produce defect free holes, the process

of drilling on nanopolymer composite laminates needs to be 1.15
observed.
1.1

5.2. Effect of tool geometry on thrust force, torque and

1.05
delamination

The drill tool geometries such as the drill diameter, point 1

Twist 120 twist 85 brad dagger step
angle, helix angle, chisel edge, rake angle and web thickness
Drill bit geometry
have shown greater effect on the thrust force, torque and
delamination while drilling FRP laminates [54–56]. The point Fig. 4 – Drill geometry influence on delamination factor [56].

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on CFRP composite laminates. Based on simulated data, the
thrust force and torque values generated by using 8 mm drill
diameter are four times higher than that of 4 mm drill diame-
ter and thrust force increases with the increase of point angle.
The thrust force and torque values increases by 88% and 400%
respectively as the web thickness increases from 0.5 to 1.1 mm.
Eneyew and Ramulu [19] conducted some preliminary exper-
iments on UD-CFRP composites using PCD tipped eight facet
drill to find out the surface quality and material damage in
drilling. During drilling of GFRP/Epoxy composites, the drill
tool geometry and tool material highly influences the cut-
ting forces and material damage. Four drills (EDP27199, A1141,
A1163 and A1167A) with different drill geometries and mate-
rials and various cutting parameters were used to test the
composite for defect free holes in drilling [57].
Velayudham and Krishnamurthy [58] have carried out a
sequence of drilling experiments to study the influence of car-
bide drills with different point geometries on thrust force and
delamination of polymeric composite laminates. Investigation
results reveals that tripod drill performs better cutting forces
compared to other drill geometries and the critical thrust force
observed when feed rate was 0.1 mm/rev, above that there was
a rapid increase in thrust results.
The drilling experiments using coated tungsten carbide
drill (ratio drill) on Glass Fiber Reinforced Epoxy (GFRE) com-
posite rods shows better machinability compared to regular
twist drill. The new drill geometry called ratio drill was used
to predict the machining parameters, flank wear, surface
roughness and circularity errors [59]. Paul et al. [44] study
reported that the conventional twist drill with 118◦ point angle
and 6 mm drill diameter exhibits the lower thrust force and
reduced delaminations in drilling of CFRP nano composite
laminates. Sachse et al. [60] have used 10 mm diameter drill
bit for drilling on PA6 nanocomposites under controlled envi-
ronment for the evaluating of emission of particles.
So, the proper selection of cutting tool geometry and
its nomenclature gives the enhanced cutting forces and
minimum material damage in drilling of FRP as well as
nanocomposites laminates.
5.3. Effect of tool types and tool materials on thrust
force, torque and delamination
Different types of drills and drill materials have greater influ-
ence on the thrust force, torque and delamination. Drilling
of GFRP composite laminates with distinct and conventional
uncoated cemented carbide drills exhibits a complete analysis
of push-out delamination and drilling load profiles.
Based on the experimental and analytical results, it was
concluded that specialized drill tools reduced the drilling
thrusts for the whole range of machining parameters com-
pared to the conventional drills and also the magnitudes of
push-out delamination damage were noticeable [61]. Adjacent
to the twist drill, the effects of different types of drills such as
core drill, step drill, saw drill and candle stick drill have exhibit
a major impact on the critical thrust force and delamination.
In case of a saw drill, the size of the delamination zone is
dependent on the thrust force applied on the FRP composite
laminate. At high thrust forces, the size of the delamination
zone is equal to the drill diameter, which is the minimum
Please cite this article in press as: Panchagnula KK, Palaniyandi K. Drilling on fiber reinforced polymer/nanopolymer composite laminates: a
review. J Mater Res Technol. 2017. http://dx.doi.org/10.1016/j.jmrt.2017.06.003
7
140
Twist drill
Saw drill
120 Core drill
Step drill
Candle stick drill
100
Thrust force (N)
80
60
40
20
0
2 4 6 8 10 12 14
Feed rate (mm/rev) x 10-3
Fig. 5 – Graphical representation of the thrust force
variation related to the feed rate for different drill tools [64].
possible delamination in case of a composite material. Also,
when the diameter of the saw drill is considered to be zero, its
behavior is analogous to twist drill with zero drill diameters
or with infinite delamination zone. In case of a candle stick
drill with zero circular load, i.e. no torsional load on the drill
bit, the working is the same as that of a twist drill with a point
load at the centerline of the drill. Also in cases where the
drill centerline load is zero, this drill is analogous to saw drill.
This is as the geometry of a saw drill does not accommodate
for centerline loads [62–64]. Fig. 5 illustrates the thrust force
variation related to the feed rate for different drill tools.
In addition to the standard drill tools, the newly micro
coated tools such as PCD tools, CBN coated tools, diamond like
coated tools coated tools, etc. were also used to acquire good
surface finish of the drilled holes with less damage [65–67].
Paul et al. [44] have selected three different types of drills;
namely, HSS drill, carbide tipped drill and solid carbide drill for
the purpose of drilling on CNF reinforced CFRP nanocomposite
laminates. The drilling defects called delamination, circular-
ity error were minimized at entry as well as exit with solid
carbide drill. Irfan et al. [68] have employed a special type
of angle drill of 10 mm diameter in drilling of Polyamide 6-
and Polypropylene-Silicon Composites for the estimation of
release of nanoparticles.
In addition to the tool geometry, the tool types and tool
materials also play a key role in drilling of FRP and nanocom-
posite laminates. The cutting forces, drilling delamination and
other induced defects were reduced by the proper selection of
drill tool types and materials.
6. Summary
Exceptional mechanical and physical properties like extraordi-
nary tensile strength, modulus, good corrosion and chemical
resistance, elevated adhesion and dynamic stability have
encouraged the use of composites in a variety of applica-
tions. The mechanical drilling of nanopolymer composite
JMRTEC-274; No. of Pages 10
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laminates differs extensively in many aspects from drilling of
conventional composite laminates. The work exhibited here
is an overview of mechanical drilling on FRP/nanopolymer
composites laminates, mainly including drilling forces, drill
tool geometry, drill tool types and materials, drilling-induced
delamination and its inhibiting approaches, sub-surface
deformation, surface roughness, and tool wear, etc. In addi-
tion to that optimization of machining parameters, drill tool
geometry and tool types are also investigated.
The cutting force analysis in drilling of nanopolymer com-
posite laminates by varying machining parameters; at a range
of 500–1500 rpm in spindle speed and 0.01–0.10 mm/rev in feed
rate [44] and varying drill sizes (5–10 mm diameter) are used
in the literature for the better understanding of force genera-
tion, cutting mechanisms and drilling induced delamination
[49,50,53].
Drilling of nanopolymer composite laminates imposes
special requirements on the tool geometry and the wear mech-
anism of the drill bit [59,60]. In addition to uncoated HSS drill,
a number of special coated drills such as carbide tipped drills,
solid carbide drills and special type of angle drills are used
for drilling of nanopolymer composite laminates to trim down
delamination damage [44].
Therefore, in order to produce defect free holes and
mechanical joining of composite structures, the process of
drilling on FRP as well as nanopolymer composite laminates
needs to be monitored.
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