Yallew2015 PDF

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Original Article
Proc IMechE Part L:

J Materials: Design and Applications
A study about hole making in woven jute 0(0) 1–11
! IMechE 2015
fabric-reinforced polymer composites Reprints and permissions:
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DOI: 10.1177/1464420715587750
pil.sagepub.com
Temesgen Berhanu Yallew, Pradeep Kumar and Inderdeep Singh
Abstract
The time has come for natural fibres to stand as potent substitutes for synthetic fibres in various industrial applications.
Recently, jute fibre is being used as reinforcement material in the development of reinforced plastics for various engin-
eering products. The production cycle of a composite product often necessitates certain degree of machining operations.
Drilling is one of the most widely practised machining operation for making holes in composite laminates. Hole making is
imperative to ascertain the assembly of intricate composite products. The literature available indicate that not much
research work has been reported on the machining behaviour of jute fibre-reinforced polypropylene composites. Hence,
in the present experimental endeavour, drilling of woven jute fabric-reinforced polypropylene composite has been
performed. The effect of operating variables on thrust force and torque signals was investigated. Drilling-induced
damage in the developed composite was quantified using stereo microscope. The experimental values indicate close
relationship between the tool geometries and the delamination factor. SEM analysis was also conducted to understand
the drilling behaviour and surface morphology of the drilled holes. Among the solid drills compared, parabolic drill
reveals better cutting behaviour in terms of lower drilling forces and better quality of holes. This may be attributed to the
better tool-work piece interaction in case of parabolic drill point geometry.
Keywords
Jute fibre, polypropylene, composites, drilling force, delamination factor
Date received: 27 August 2014; accepted: 29 April 2015
Introduction
with conventional drilling is that it comes with various
The time has come for natural fibres to stand as forms of damage that seriously affects the strength of
potent substitutes for synthetic fibres in a number of components with holes made by drilling. Worse, the
industries. Natural fibres are growing popular with damage could seriously affect the mechanical proper-
time in proportion to the appreciation of their ties of the composite, even to the extent of shortening
unique qualities. Among others, natural fibres can the life span – hence, the value – of the product.
be used as reinforcement materials in thermoset as Needless to say, to the extent that we cannot do with-
well as thermoplastic composites. Natural fibres are out machining, there is a need to come up with some
unrivalled for their friendliness to environment, which potent means to address the inherent drawbacks of
is a combination of their ultimate disposability after conventional drilling, which could challenge the very
an optimal use of raw materials.1 worth of natural fibre-reinforced composites.3
Tight knitting is involved in the making of com- There have been some suggestions as well, includ-
posite materials, but there always is a need for ing by Caprino et al.4 in their report on drilling-
machining. Most often than not, the need to come induced damage on glass composite. The damage
up with complex shapes of moulds necessary for the caused by standard conventional tools was found to
purposes of filtering calls for the additional surplus be highly dependent on the extent of feed. The higher
material. The removal of such surplus with the view the feed, the more pronounced the features that are
to make the product ready for assembly makes the
employment of machining mandatory. This is more
apparent in the production and assembly of automo- Department of Mechanical and Industrial Engineering, Indian Institute of
tive parts where accuracy in the drilling of holes to Technology, Roorkee, Roorkee, Uttrakhand, India
join pieces is part of the necessary process.2
Corresponding author:
The most common way to make holes in composite Temesgen Berhanu Yallew, Department of Mechanical and Industrial
laminates is of course conventional drilling, while dif- Engineering, Indian Institute of Technology, Roorkee, Uttrakhand, India.
ferent methods have been put to use. The problem Email: temesgenu11@gmail.com
Downloaded from pil.sagepub.com at University of Hawaii at Manoa Library on June 10, 2015
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2 Proc IMechE Part L: J Materials: Design and Applications 0(0)
characteristic of impact damage – layers, cracks and feed rate and drill point geometry on the drilling
high density micro failure zones. These values came behaviour of natural fibre composites. The objective
down with decreased feed and the failure defects of the present endeavour is to experimentally investi-
remained limited to the delamination at the junction gate the effect of different process parameters (cutting
point where the nose of the drill passed leaving the speed, feed rate and drill point geometry) on drilling
mouth of the hole open. Reduced feed generally kept behaviour of woven jute fabric-reinforced polypropy-
the damage to the point of the hole made by the drill. lene-based composites.
On the other hand, Caprinot and Tagliaferri5 ques-
tioned the relevance of microscopic surface observa-
tions to loss of mechanical behaviour when carbon Materials and experimental details
and glass fibre epoxy composites are machined.
Materials (specimen composition)
There is a tendency in the brittleness of the material
to add to the damage induced by machining. The basic raw materials used to prepare the experi-
Another factor reported by Vijayaraghavan6 is that mental composites are polypropylene (PP) pellets, as
increase in the drilling thrust force results in greater matrix material, and jute fabrics (in the form of
delamination of fibre-reinforced polymer, which in woven fabric), as reinforcement. The PP was supplied
turn creates greater edge defects. Mihoc et al.7 by Reliance Industries Limited, ParcChembur,
looked into the relationship between the geometry Mumbai, India, in the form of homo polymer pellets.
of drilling tools and the specific nature of composite The polymer has a density of 0.905 g/cm3 at room
materials in order to identify hole delamination as the temperature. The melting temperature (Tm) and melt
singular defect. flow index are 165 C and 10.5 g/10 min, respectively.
Chandramohan and Marimuthu8 report a related The jute fibre in the form of woven fabric was sup-
conclusion – though limited to torque and cutting plied by Women’s Development Organization
speed – on the relationship between cutting speed, (WDO), Dehradun, Uttarakhand, India.
thrust force and feed rate in drilling of natural fibre-
reinforced thermoset polymer. At a lower feed rate,
Specimen fabrication
cutting speed has no significant effect on thrust force.
However, the higher the feed rate, the lower the thrust In order to perform the experimental work, initially,
force with increasing cutting speed. Also, increase in polypropylene sheets of size 150 mm 80 mm 1 mm
cutting speed resulted in a slight rise in torque. The were prepared by melting and compressing pre-
researchers further reported a positive correlation weighed polypropylene pellets on a compression
between torque and feed rate as well as between mould set-up, which consists of a mould set with heat-
torque and fibre volume fraction. ing arrangement. The woven jute fabric and the poly-
Babu et al. 9 reported their findings of a multiple mer sheets were stacked alternatively in a metallic
regression analysis establishing a relationship between mould. The woven jute fabric was always kept
feed rate, cutting speed, delamination factor and between the two polymer sheets. To avoid sticking
roughness of hole surface. In conclusion, they identi- of polymer sheets to the mould plates, 2 mm thick
fied cutting speed and feed rate as main causes of TeFon sheets were used on the top and bottom of
delamination in the developed hemp fibre-reinforced the mould plates. The melting point of TeFon sheet
polyester composite. Overall, it was concluded that, is too high as compared to the working temperature
the higher the cutting speed and the lower the feed of PP polymer. The whole assembly was hot-pressed
rate, the lower was the delamination. at a temperature of 165 C, and a high pressure of
As could be seen from the forgoing discussion, the 4 MPa, for 8 min. At this temperature, PP polymer
diversity in the physical characteristics of various melts and impregnates the jute fabric and compaction
composites results in different effects on the machin- takes place. The pressure was subsequently increased
ing process. Solving the problem of drilling-induced to 6 MPa for 2 min, and then the composite was
damage for natural fibre composites is vital. It almost cooled under pressure. Finally, the composite lamin-
determines their worth as parts of equipment. While ates were removed from the mould when the tempera-
research has been conducted on the behaviour of ture reached 80 C. The schematic of the composite
thermoset polymer composites under drilling, it is fabrication process is shown in Figure 1.
hard to find any study on natural fibre reinforced
thermoplastic polymer composites, especially the dril-
Mechanical behaviour of developed composites
ling behaviour of woven jute fabric-reinforced
thermoplastic polymer composites. Representative specimens from various sections of the
Given the risk of damage caused by drilling on the composite were prepared, according to ASTM D638
worth of the composites, it is crucial to investigate and and ASTM D790 standard, to examine the tensile and
establish their behaviour under drilling. bending (flexural) strength of the composites, respect-
To that end, there is a need to conduct an experi- ively. The size of the sample used for tensile strength
mental investigation on the effect of cutting speed, test was 165 mm 19 mm 3.2 mm, and of one used
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Yallew et al. 3
Figure 1. Schematic of fabrication process for woven jute fabric-reinforced PP composite laminates.
Table 1. Drilling process parameters. The schematic of experimental set-up and the mod-
elled drill geometries are shown in Figures 2 and 3,
Levels
respectively. The work pieces (with 40% Jute fibre
Factor Symbol Unit 1 2 3 reinforcement) for drilling were prepared by cutting
(in a band saw) the fabricated composite sheet into
Cutting speed v rpm 900 1800 2800 smaller sizes of 50 mm 50 mm 4 mm for holding it
Feed rate f mm/rev 0.05 0.12 0.19 conveniently in the machine.
for the three-point bending test, 76 mm 25 mm

Phases of drilling
3.2 mm with span length of 56 mm. The tests were In this experimental study, a four component, piezo-
done using a Kalpak Computerized Universal testing electric drill dynamometer (Kistler -Type 9272) was
machine (model KIC-2-XXX-C with Series IX soft- used to measure the thrust force and torque during
ware, Canton, MA, USA), which has a maximum the drilling process. The composite laminate speci-
capacity of 30 kN. All tests were performedwith a mens were clamped to the dynamometer with work
crosshead speed of 1 mm/min at room temperature holding fixture of two steel plates with a central hole
(25 C) and at a percentage relative humidity of 50. of diameter 20 mm. The three drill point geometries
Five specimens were tested for each sample and the used for the present experimental investigation are
mean values are reported. shown in Figure 3. Experimental set-up details are
depicted in Figure 2. Model drilling process and
phases in drilling are shown in Figures 4 and 5,
Drilling activity
respectively.
Batliboi Pvt. Ltd., Surat, India, radial drill machine,
with rotational spindle speeds (range from 90 to
4500 rpm) and longitudinal feeds (range from 0.03
Delamination observation
to 0.3 mm/rev) with 1.5 KW/1420 rpm, power/speed The surface damage due to delamination while drilling
of drilling main motor, and 0.75 KW/1420 rpm, of the specimen was analysed, using Nikon (Type 104,
power/speed of Elevating motor, was used for drilling SMZ 7457, Japan) Stereo Microscope. Magnification
the specimens. All specimens were drilled using 118 of 1 (one time) was used to clearly visualise the
point angle solid carbide tool material with two-fluted damaged zone around the drilled hole and VUE
standard Twist drills, Jo drills, and parabolic drills of 2014 software was used for image processing.
8 mm diameter. The experiments were conducted Figures 6 and 7 show schematic of delaminated speci-
without backing plate and coolant. The process par- men and mechanism of delamination, respectively.
ameters for the drilling of the composite laminate are
illustrated in Table 1. The values are selected based on Dmax
F¼
the optimal drill effect on the quality of drilled holes D
and drilling machine set-up specification.
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Figure 2. Schematic diagram of experimental set-up.
Figure 3. Drill geometries: (a) twist drill, (b) Jo drill and (c) parabolic drill.
Figure 5. Phases of drilling in the composite laminate.
Figure 4. Modelled drilling process.
where Dmax is the maximum diameter of the delamin-

ation zone in mm and D is diameter of the drill in mm.
SEM study
Morphological observation of selected drilled speci-
men holes was performed at room temperature Figure 6. Schematic of delaminated specimen.
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Yallew et al. 5
fully impregnate the fibres, thus leading to poor inter-

facial bonding and consequently lower mechanical
properties. Thus, poor wetting results in poor stress
transfer efficiency across the fibre–resin interface,
which leads to agglomeration, and stress transfer
gets hindered. As a result, there is a decreasing
trend in tensile strength with increasing fibre content
in the composite. On another hand, the increase in
jute fibre content in the matrix results in an increase
in the modulus of the composites. Furthermore, the
enhancement in tensile modulus is more significant
provided that the fibre content is greater than 40 wt.
%. It is well known that incorporation of fibre into
the polymer matrix reduces matrix mobility, resulting
in a stiffened composite. As a result, tensile modulus
increased with increasing fibre content of the
composites.10,11
The SEM images of the tensile fracture surface
morphologies of jute–PP composites prepared with
Figure 7. Schematics of delamination mechanism. (a) Peel-up 30, 40 and 50 wt.% of jute are shown in Figure 9.
and (b) push-down. The morphological properties of the tensile fractured
surface show the variation in mechanical properties
through phase information of the fabricated compos-
ites specimens. Figure 9(c) shows that a large number
of fibre bundles were found, which indicate that these
fibres were not properly wet by the PP resin and thus
led to poor stress transfer efficiency. It was also
observed that relatively less fibre pull-outs and
debonding were observed for 40 wt.% fibre reinforce-
ment. Moreover, 40 wt.% jute–PP composite shows
better distribution of the fibre in to the matrix,
which helps in better interfacial tie between the
jute fibre and matrix. The effect of better interfacial
bonding between the jute fibre and the matrix is
clearly observed in the mechanical properties
Figure 8. Effect of jute fibre wt.% on tensile behaviour. improvement.12
using model XL 30, Philips Scanning Electron

Flexural strength
Microscope (SEM). The specimen was coated with a Figure 10 illustrates the flexural strength and modulus
very thin film of gold using Sputter Coater to enhance of jute fibre-reinforced composite at different weight
conductivity before micrographs were taken. percentage. The flexural strength goes up linearly with
an increase in the amount of jute fibre reinforcement
up to 40%; then, abruptly, the value of the strength
Results and discussion starts going down while the fibre reinforcement was
further increased. This may be due to the balanced
Mechanical properties effect of the favourable entanglement of the polypro-
Tensile property. Jute fibre reinforcement effect on the pylene with the jute fibre and an opposing weak fibre–
tensile strength and tensile modulus of polypropylene matrix interfacial adhesion with increasing fibre
matrix is demonstrated in Figure 8. As depicted in the reinforcement content in the composite. In contrast
figure, the tensile strength increased linearly up to to Fexural strength, the Fexural modulus exhibited
40 wt.%, after that it tends to decrease despite the an increasing trend with an increase in amount of
further rise in the wt.% of fibre reinforcement. This fibre reinforcement.10,11
may be associated with the fact that, as the wt.% of Table 2 gives the values of standard deviation cal-
the reinforcement fibre increased, the weak interfacial culated for mechanical properties of woven jute
area and the micro spaces increased between the fibre fabric-reinforced polypropylene laminates. The vari-
and the matrix, accordingly bringing down the tensile ation in the mechanical properties (tensile and flex-
strength. It is also true that, at high percentage ural) due to the change in the wt.% (jute fibre
reinforcement, it is more difficult for the resin to loading) is statistically significant.
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Figure 9. SEM micrograph of tensile fractured surface of jute fibre-reinforced PP composite at wt. % of fibre: (a) 30%, (b) 40%
and (c) 50%.
Table 2. Standard deviation values for mechanical properties.
Wt. % Tensile Tensile Flexural Flexural

(jute fibre loading) strength modulus strength modulus
30 2.35 11.94 2.13 0.40

40 1.74 11.27 1.49 0.16
50 0.86 11.79 1.46 0.59
observed that the drilling process has three different

phases. Phase 1 shows the sharp increment of thrust
force and torque signals as the tool touches the spe-
Figure 10. Effect of jute fibre wt.% on flexural behaviour.
cimen. Phase 2 shows the steady zone of drilling where
actual machining or cutting of composite laminate
(specimen) occurs. Final phase 3 shows the decreasing
of drilling signals, which is due to less contact of com-
Drilling thrust force and torque signal analysis posite laminate (specimen) parts with the drill bit and
In this experimental study, drilling signals were the beginning of the drill bit exit out of the composite
detected using a four-component, piezoelectric drill laminate.
dynamometer (Kistler -Type 9272).Typical phases of The solid drills (twist, Jo and parabolic) have simi-
drilling are depicted in Figures 11–13. Figure 11 pre- lar material removal mechanisms. These drills have
sents thrust force and torque signals using solid Twist two cutting edges and drilling begins from the chisel
drill point geometry. Figure 12 describes thrust force edge (centre drill). During the drilling operation of the
and torque signals using solid Jo drill geometry and composite laminate, the uncut part below the drill bit
Figure 13 shows thrust force and torque signals using acts as an overhanging beam which is pushed down by
solid parabolic point geometry. It can be clearly the movement of the drill point. The drilling
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Yallew et al. 7
Figure 11. Thrust force and torque signals with twist drill (900 rpm and 0.12 mm/rev.).
Figure 12. Thrust force and torque signals with Jo drill (900 rpm and 0.12 mm/rev.).
parameters have an influence in the size and shape of signals recorded with different drill geometries. The
the material removed in the form of chips. experimental data of thrust force with variation of
As shown in Figures 11–13, parabolic drill shows operating parameters is presented in Figures 14
better cutting behaviour than the Jo drill and twist and 15.
drill in terms of lower drilling forces. This may be It is clearly seen from Figure 14 that there is a
due to less drill contact with the composite laminate constant or decreasing effect on thrust force with an
(specimen) resulting in thrust force and torque signals increase in the cutting speed for all the drill bit types
which provides better quality drilled hole (lower used in experimentation (keeping the feed rate con-
delamination factor) than the Jo and Twist drill. stant at 0.12 mm/rev). But as depicted in Figure 15,
The machining mechanism with different drill geo- there is an increase in thrust force values with the
metries as stated above have a direct influence on the increase of feed rate (keeping the cutting speed con-
drilling thrust force and torque signals. It is also true stant at 1800 rpm) for all the drill bit types investi-
that the thrust force and torque signals vary with gated. There is a significant difference in the thrust
operating parameters. The drilling-induced damage force values with the same drilling parameter values
is highly affected by the thrust force and torque with the different drilling geometries, especially the
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Figure 13. Thrust force and torque signals with parabolic drill (900 rpm and 0.12 mm/rev).
Figure 14. Variation of thrust force with cutting speed Figure 16. Variation of torque with cutting speed keeping the
keeping the feed rate constant at 0.12 mm/rev. feed rate constant at 0.12 mm/rev.
Figure 15. Variation of thrust force with feed rate keeping Figure 17. Variation of torque with feed rate keeping the
the cutting speed constant at 1800 rpm. cutting speed constant at 1800 rpm.
difference is substantial between parabolic drill geom- twist, Jo, and parabolic drills. As depicted in
etry and the other drills used in this study. Similar Figure 16, the torque decreases for twist and Jo drill
trends were shown by other authors.13,14 and increases for parabolic drill with the increase of
Figures 16 and 17, respectively, show the torque cutting speed (keeping the feed rate constant at
variation with the operating parameters for the 0.12 mm/rev).
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Yallew et al. 9
Figure 18. Drilling-induced damage in woven jute fabric-reinforced composite laminates with (a) twist drill, (b) Jo drill and
(c) parabolic drill.
Whereas Figure 17 demonstrates the increase of the

torque values with the increase of feed rate for all the
drill geometries involved in the experiment (keeping
the cutting speed constant at 1800 rpm). Earlier stu-
dies have also investigated the variation of torque
during drilling of composite laminates using different
drilling tools.13,14
Delamination and analysis of delamination factor

Delamination is a frequent cause of damage in the
drilling of composite laminates .While drilling of the
Jute fibre-reinforced composites, damage was Figure 19. Variation of delamination factor with feed rate
observed both at the entry and exit of the specimen. keeping the cutting speed constant at 1800 rpm.
The delamination observed is due to peel-up and
push-out mechanisms associated with drilling compos-
ite laminates and the main cause of delamination is the
thrust force. In our experimental observation, we have
seen that the push-out delamination was more severe
than that of the peel-up. In drilling of composite
laminates, the uncut thickness of the specimen to with-
stand the drilling thrust force decreases as the drill
approaches the exit plane of the specimen. The lamin-
ate at the bottom may get separated from their inter-
laminar bond around the hole. At some point, the
loading exceeds the interlaminar bond strength and
delamination occurs. This happens before the laminate
is completely penetrated by the drill.
The drilling induced damage, that is, delamination
Figure 20. Variation of delamination factor with cutting
was quantified using stereomicroscope, and the dril- speed keeping the feed rate constant at 0.12 mm/rev.
ling-induced damage in woven jute fabric-reinforced
composite laminates is depicted in Figure 18. It is
clearly noted that the delamination for the composite there is a decrease in values of delamination factor
laminates drilled using twist drill geometries values with an increase of cutting speed in the Twist
(Figure 18(a)) is higher than the other drill geometries and Jo drill geometries, but a slight increase in delam-
(Jo drill, Figure 18(b) and paraboilic drill ination factor values observed with the parabolic drill
(Figure 18(c)). Figures 19 and 20 show the variation geometry. It is important to investigate the drilling
of delamination factor values with the operating par- behaviour of jute fabric-reinforced composites. The
ameters (cutting speed and feed rate). Figure 19 shows drilling behaviour of woven jute fabric-reinforced
that with an increase of feed rate, there is correspond- polypropylene composites is different from other
ing increase in delamination factor in case of Twist types of composites. It has been found by authors in
and Jo drill geometries but there is a slight decrease in earlier investigations that Jo drill performs better for
delamination factor values in case of parabolic drill glass fibre-reinforced epoxy laminates whereas, para-
geometry. On the other hand, Figure 20 shows that bolic drill performs well in the case of jute fibre-
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Figure 21. SEM image of drilled hole with feed rate 0.12 mm/rev, cutting speed 2800 rpm using (a) twist drill, (b) Jo drill and
(c) parabolic drill geometries.
reinforced laminates. This may be attributed to the As shown in Figure 21(a), twist drill has greater
difference in the physical and chemical properties of drilling induced damage with large pullouts and
the fibres. high surface roughness. This is due to the high drilling
force established which caused large damage zone
around the drilled hole. As depicted in Figure 21(b),
SEM investigation of drilled holes Jo drills show fibre and matrix separation inside the
The microstructural view at different locations in drilled hole but has improved drilled wall roughness
walls of drilled holes was examined at room tempera- than the twist drill. The SEM image for drilled hole
ture using model XL 30, Philips, scanning electron with parabolic drill is shown in Figure 21(c), the para-
microscope. The SEM photographs (Figure 21) bolic drill shows better cutting behavior with less dril-
show the drilled surface microstructure such as fibre ling-induced damage around the drilled hole, than the
and matrix deterioration, and drilled wall surface Jo drill and Twist drill. This may be due to less drill
roughness of the drilled woven jute fabric-reinforced contact with the composite laminate (specimen)
polypropylene composite laminate using the twist, Jo, resulting in lower thrust force and torque signals
and parabolic drill geometries at a feed rate of 0.12 which provides better quality drilled hole (lower
rev/min and cutting speed of 2800 rpm. delamination factor) than the Jo and Twist drill.
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Yallew et al. 11
Funding
Conclusions
This research received no specific grant from any funding
In the present experimental investigation, woven jute agency in the public, commercial, or not-for-profit sectors.
fabric-reinforced polypropylene composites were fab-
ricated. Drilling behavior of the developed composites References
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10. Sangthong S, Pongprayoon T and Yanumet N.
5. It is noted that the delamination factor values for
Mechanical property improvement of unsaturated poly-
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twist drill geometries are higher than the other fibres. Compos: Part A 2009; 40: 687–694.
drill geometries. Therefore, twist drill point geom- 11. El-Shekeil YA, Sapuan SM, Abdan K, et al. Influence
etry which is used for metals extensively is not of fibre content on the mechanical and thermal proper-
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can also be investigated in future and the drilling
performance can be compared with the solid drill
point geometries.

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XML Template (2015) [14.5.

Proc IMechE Part L:

Temesgen Berhanu Yallew, Pradeep Kumar and Inderdeep Singh

Date received: 27 August 2014; accepted: 29 April 2015

2 Proc IMechE Part L: J Materials: Design and Applications 0(0)

for the three-point bending test, 76 mm 25 mm

4 Proc IMechE Part L: J Materials: Design and Applications 0(0)

Figure 2. Schematic diagram of experimental set-up.

Figure 5. Phases of drilling in the composite laminate.

Figure 4. Modelled drilling process.

where Dmax is the maximum diameter of the delamin-

fully impregnate the ﬁbres, thus leading to poor inter-

using model XL 30, Philips Scanning Electron

6 Proc IMechE Part L: J Materials: Design and Applications 0(0)

Table 2. Standard deviation values for mechanical properties.

Wt. % Tensile Tensile Flexural Flexural

30 2.35 11.94 2.13 0.40

observed that the drilling process has three diﬀerent

8 Proc IMechE Part L: J Materials: Design and Applications 0(0)

Whereas Figure 17 demonstrates the increase of the

Delamination and analysis of delamination factor

10 Proc IMechE Part L: J Materials: Design and Applications 0(0)

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