Skip to main content

Carbon Fibre Reinforced Polymer (CFRP) Composites: Machining Aspects and Opportunities for Manufacturing Industries

  • Chapter
  • First Online:
Composite Materials: Applications in Engineering, Biomedicine and Food Science

Abstract

Carbon fibre reinforced polymer (CFRP) composite is becoming popular in supply and demand trend among the industry players especially in aerospace industry. This material can be applied into various applications in the industries due to the features such as strength-to-weight ratio and rigidity, which is suitable for the aircraft with the highest weight ratio or low weight for high-performance automobile racing. This chapter covers comprehensively regarding CFRP and their machinability. The first section explains three major types of composite materials and its features including a brief highlight about the development of composite materials. Next section covers the fundamental of machining characteristics and the tool development, which is focusing on the machining of fibre reinforced polymer composites. Furthermore, this section focuses on drilling aspects because it is the most challenging machining process compared with sawing, planning, turning, milling and other conventional machining process. The third section highlights the development of drilled hole measurement techniques, which focusing on the prominent development of the delamination factor (Fd) ratio. The final part summarizes the outlook of exploiting this composite material in term of machining parameters. This chapter reviews the experimental progress in drilling of CFRP composites, which is intended to help readers to obtain the latest views in order to develop the appropriate machining parameters.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 189.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 249.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 249.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Similar content being viewed by others

References

  • Abrate S, Walton DA (1992) Machining of composite materials, Part II: Non-traditional methods. Compos Manuf 3(2):85–94

    Google Scholar 

  • Askeland DR, Phulé PP (2006) The science and engineering of materials (International Student Edition). Thomson Publishing

    Google Scholar 

  • Brouwer WDR (2019) Natural Fibre Composites in Structural Components: Alternative Applications for Sisal? http://www.fao.org/DOCREP/004/Y1873E/y1873e0a.htm (Accessed on 16th April 2019)

  • Caggiano A, Nele L, Teti R (2018). Drilling of Fiber-Reinforced Composite Materials for Aeronautical Assembly Processes, Characterizations of Some Composite Materials, Hosam El-Din M. Saleh and Martin Koller, IntechOpen, DOI: https://doi.org/10.5772/intechopen.80466. Available from: https://www.intechopen.com/books/characterizations-of-some-composite-materials/drilling-of-fiber-reinforced-composite-materials-for-aeronautical-assembly-processes

  • Chen WC (1997) Some experimental investigation in the drilling of carbon fiber reinforced plastic (CFRP) composite laminates. Int J Mach Tools Manuf 37:1097–1108

    Google Scholar 

  • Dandekar CR, Shin YC (2012) Modelling of machining of composite materials: a review. Int J Mach Tool Manu. https://doi.org/10.1016/j.ijmachtools.2012.01.006

  • Davim JP, Reis P (2003) Drilling carbon fibre reinforced plastics manufactured by autoclave – experimental and statistical study. Materials & Design 24(2003):315–324

    CAS  Google Scholar 

  • Davim JP, Rubio JC, Abrao AM (2007) A novel approach based on digital image analysis to evaluate the delamination factor after drilling composite laminates. Compos Sci Technol 67:1939–1945

    Google Scholar 

  • Di Ilio AM, Tagliaferri V, Veniali, F (1991) Tool life and hole quality in drilling aramid and fibrous composites, in Composite Material Technoloav 1991. Proc of 14th Annual Energv Sources Technology Conf. ahd Exhibition, Houston, TX, Jan 2{123,1991, ASME Publ. PD-Vol 37, pp 203–207

    Google Scholar 

  • Faraz A, Biermann D, Weinert K (2009) Cutting edge rounding: an innovative tool wear criterion in drilling CFRP composite laminates. Int J Mach Tool Manu 49:1185–1196

    Google Scholar 

  • Franke V (2011) Drilling of long fiber reinforced thermoplastics-influence of the cutting edge on the machining results. CIRP Ann Manuf Technol 60:65–68

    Google Scholar 

  • Garrick R (2007) Drilling Advanced Aircraft Structures with PCD (Poly-Crystalline Diamond) Drills, SAE Technical Paper 2007-01-3893, https://doi.org/10.4271/2007-013893

  • Gaitonde vVN, Karnik SR, Campos RJ, Esteves CA, Abrao AM, Davim JP (2008) Analysis of parametric influence on delamination in high-speed drilling of carbon fiber reinforced plastic composites. J Mater Process Tech 203:431–438

    CAS  Google Scholar 

  • Gindy NNZ (1988) Selection of drilling conditions for glass fibre reinforced plastics. Int J Research 25(8):1317–1327

    Google Scholar 

  • Hernandez-Castaneda JC, Sezer HK, Li L (2011) The effect of moisture content in fibre laser cutting of pine wood. Opt Lasers Eng 49:1139–1152

    Google Scholar 

  • Hickey J (1987) Drilling graphite composites. Modern Machine Shop 59:84–90

    Google Scholar 

  • Hintze W, Hartmann D, Schutte C (2011) Occurence and propagation of delamination during the machining of carbon fibre reinforced plastics (CFRPs)-an experimental study. Compos Sci Tecnol 71:1719–1726

    CAS  Google Scholar 

  • Hocheng H, Dahran CKH (1990) Delamination during drilling in composite laminates. J Eng of Indusry 112:236–239

    Google Scholar 

  • Hocheng H, Tsao CC (2006) Effect of special drill bits on drilling-induced delamination of composite materials. J Mach Tools Manu 46:1403–1416

    Google Scholar 

  • Iliescu D, Gehin D, Gutierrez ME, Girot F (2010) Modelling and tool wear in drilling CFRP. Int J Mach Tool Manu 50:204–213

    Google Scholar 

  • Jain S, Yang DCH (1994) Delamination-free drilling of composite laminates. ASME J Eng Indust 116:475–481

    Google Scholar 

  • Kalpakjian S, Schmid SR (1999) Manufacturing engineering and technology (international edition). Pearson Publishing, Fourth Edition

    Google Scholar 

  • Kalpakjian S, Schmid SR (2016) Chapter 9 Composite materials: structure, general properties and applications https://www3.nd.edu/~manufact/MET_pdf_files/MET_Ch9.pdf (Accessed on 26th November 2016)

  • Kim GW, Lee KY (2005) Critical thrust at propagation of delamination zone due to drilling of FRP/metallic strips. Compos Struct 69:137–141

    Google Scholar 

  • Komanduri R (1997) Machining fiber-reinforced composites. Mech Eng. (ISSN 0025–6501) 115(4):58–64

    Google Scholar 

  • Konig W, Grass P, Heintze A, Okcy F, Schmitz-Justin C (1984) Developments in drilling & contouring composites containing Kevlar. Prod Eng 63(8):56–61

    Google Scholar 

  • Konig W, Wulf Ch, Grass P, Willerscheid H (1985) Machining of fiber reinforced plastics. Ann CIRP 34(2):537–548

    Google Scholar 

  • Konig W, GraS P (1989) Quality definition and assessment in drilling of fibre reinforced thermosets. Annals of the CIRP 38(1):119–124

    Google Scholar 

  • Koplev A, Lystrup A, Vorm T (1983) The cutting process, chips, and cutting forces in machining CFRP. Composites 14(4):371–376

    Google Scholar 

  • Lambert BK (1987) Cutting and drilling of composite materials. Carbide and Tool J 19(5):31–34

    CAS  Google Scholar 

  • Lau WS, Yue TM, Lee TC, Lee WB (1995) Un-conventional machining of composite materials. J Mater Process Technol 48:199–205

    Google Scholar 

  • Liu DF, Tang YJ, Gong WL (2012) A review of mechanical drilling for composite materials. Compos Struct 94:1265–1279

    Google Scholar 

  • Mackey BA (1980) How to drill precision holes in reinforced plastics in a hurry. Plast Eng:22–24

    Google Scholar 

  • Mangalgiri PD (1999) Composite materials for aerospace applications. Bull Mater Sci 22(3):657–664

    CAS  Google Scholar 

  • Matthews FL, Rawlings RD (1999) Composite materials: engineering and science, vol 2000. CRC Press, Boca Raton, pp 1351–1366

    Google Scholar 

  • Mishra R, Malik J, Singh I, Davim JP (2010) Neural network approach for estimate the residual tensile strength after drilling in uni-directional glass fiber reinforced plastic laminates. Mater Des 31:2790–2795

    CAS  Google Scholar 

  • Pecat O, Rentsch R, Brinksmeier E (2012) Influence of milling process parameters on the surface integrity of CFRP. Procedia CIRP 2012(1):466–470

    Google Scholar 

  • Radkakrishnan T, Wu SM (1981) On-line hole quality evaluation for drilling composite materials using dynamic data. Z Eng for Industry 103:119–125

    Google Scholar 

  • Ramulu M, Branson T, Kim D (2001) A study on the drilling of composite and titanium stacks. Compos Struct 54:67–77

    Google Scholar 

  • Reza N (2010) Laser cutting of carbon fibre-reinforced polymer composite materials. PhD thesis, the University of Manchester

    Google Scholar 

  • Sadat AB (1990) Machining of composites. Encyclopedia of Composites 3(1990):95–102

    Google Scholar 

  • Sakuma K, Yokoo Y, Seto M (1984) Study on drilling of reinforced plastics (GFRP and CFRP). Bulletin of JSME 27(228):1237–1244

    Google Scholar 

  • Sardiñas RQ, Reis P, Davim JP (2006) Multi-objective optimization of cutting parameters for drilling laminate composite materials by using genetic algorithms. Compos Sci Technol 66(15). 1 December 2006:3083–3088

    Google Scholar 

  • Shanmugam DK, Chen FL, Siores E, Brandt M (2002) Comparative study of jetting machining technologies over laser machining technology for cutting composite materials. Compos Struct 57(1–4):289–296

    Google Scholar 

  • Santhanakrishnan G, Krishnamurthy R, Malhotra SK (1988) Machinability characteristics of fibre reinforced plastics composites. J Mech Work Technol 17:195–204

    CAS  Google Scholar 

  • Schrader GF, Elshennawy AK (2000) Manufacturing processes & materials, Society of Manufacturing Engineers (SME), 4th Edition

    Google Scholar 

  • Sedlacek J, Slany M (2010) Analysis of delamination in drilling of composite materials. MM Sci J

    Google Scholar 

  • Sheikh-Ahmad JY (2009) Machining of polymer composites. Springer, New York

    Google Scholar 

  • Shyha IS, Aspinwall DK, Loo SL, Bradley S (2009) Drill geometry and operating effects when cutting small diameter holes in CFRP. Int J Mach Tool Manu 49:1008–1014

    Google Scholar 

  • Shyha IS, Soo SL, Aspinwall DK, Bradley S (2010) Effect of laminate configuration and feed rate on cutting performance when drilling holes in carbon fibre reinforced plastic composites. J Mater Process Technol 210(8):1023–1034

    CAS  Google Scholar 

  • Sobri SA, Heinemann R, Whitehead D, Shuaib N (2018) Drilling strategy for thick carbon Fiber reinforced polymer composites (CFRP): a preliminary assessment. J Eng Tech Sci 50(1):21–39. https://doi.org/10.5614/j.eng.technol.sci.2018.50.1.2

    Article  CAS  Google Scholar 

  • Stone R, Krishnamurthy KA (1996) Neural network thrust force controller to minimize delamination during drilling of graphite-epoxy laminates. Int J Mach Tools Manuf 36:985–1003

    Google Scholar 

  • Teti R (2002) Machining of composite materials. CIRP Ann-Manuf Techn 51(2):611–634

    Google Scholar 

  • Wong TL, Wu SM, Croy GM (1982) An analysis of delamination in drilling composite materials. In: Proc 14th SAMPE tech Conf, pp 471–483

    Google Scholar 

  • Zhang H, Chen W, Chen D, Zhang L (2001) Assessment of the exit defects in carbon fibre-reinforced plastic plates caused by drilling. Key Eng Mater 196:43–52. ISSN 1013-9826

    Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Sharizal Ahmad Sobri .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2020 Springer Nature Switzerland AG

About this chapter

Check for updates. Verify currency and authenticity via CrossMark

Cite this chapter

Sobri, S.A., Heinemann, R., Whitehead, D. (2020). Carbon Fibre Reinforced Polymer (CFRP) Composites: Machining Aspects and Opportunities for Manufacturing Industries. In: Siddiquee, S., Gan Jet Hong, M., Mizanur Rahman, M. (eds) Composite Materials: Applications in Engineering, Biomedicine and Food Science. Springer, Cham. https://doi.org/10.1007/978-3-030-45489-0_2

Download citation

Publish with us

Policies and ethics