Chapter 5: Comprehensive study on tool wear during machining of fiber-reinforced polymeric composites

Abstract

The use of fiber reinforced polymeric (FRP) composites has increased

rapidly, especially in many manufacturing (aerospace, automobile and construction)

industries. The machining of composite materials is an important manufacturing

process. It has attracted several studies over the last decades. Tool wear is a key factor

that contributes to the cost of the machining process annually. It occurs due to sudden

geometrical damage, frictional force and temperature rise at the tool-work interaction

region. Moreover, tool wear is an inevitable, gradual and complex phenomenon. It

often causes machined-induced damage on the workpiece/FRP composite materials.

Considering the geometry of drill, tool wear may occur at the flank face, rake face

and/or cutting edge. There are several factors affecting the tool wear. These include, but are not limited to, drilling parameters and environments/conditions, drill/tool

materials and geometries, FRP composite compositions and machining techniques.

Hence this chapter focuses on drilling parameters, tool materials and geometries,

drilling environments, types of tool wear, mechanisms of tool wear and methods

of measurement of wear, effects of wear on machining of composite materials and

preventive measures against rapid drill wear. Conclusively, some future perspectives

or outlooks concerning the use of drill tools and their associated wears are elucidated,

especially with the advancement in science and technology