Journal of Materials Research and Technology

An Experimental Investigation on Surface Roughness in the Drilling of Carbon Fiber

Reinforced Aluminium (AA6061-T6) Sandwich Composite Material using Response
Surface Methodology (RSM)
--Manuscript Draft--

Manuscript Number:

Article Type: Original article

Keywords: Drilling, Carbon Fiber Reinforced Aluminium Sandwich (CFRP), Analysis of Variance
(ANOVA), Response Surface Methodology (RSM), Surface roughness

Corresponding Author: tamilarasan uthirapathy, ph.d

Sri Sai Ram Engineering College
chennai, tamilnadu INDIA

First Author: tamilarasan uthirapathy, ph.d

Order of Authors: tamilarasan uthirapathy, ph.d

Dr. Karunamoorthy L

Dr. Palanikumar K

Abstract: In the present investigation, the drilling experiments are carried out to analyse the
performance of surface roughness in drilling CFRP aluminium (6061-T6) sandwich
laminates. Aluminium (AA6061-T6) is used as a sandwich material in the fabrication of
CFRP composite laminate. In machining of fibre metal laminate, surface roughness is a
very important parameter, which has to be minimized to carry out a defect free drilling
process. The three process parameters, spindle speed, feed rate and point angle of
the drill are chosen according to the Taguchi's orthogonal array design procedure. The
experimental results are analysed by using Response Surface Methodology (RSM).
The surface morphology of the machined surface is analysed by using Scanning
Electron Microscope (SEM). ANOVA is carried out to check the adequacy of the
developed model.

Suggested Reviewers: Dr.Vijayaramnath B

hod.mech@sairam.edu.in
He's specialized in composite materials

Dr.Mohan B
bmohan@annauniv.edu
He's Specialized in composite Materials

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drgbbhaskar@annauniv.edu
He's specialized in composite materials

Opposed Reviewers:

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Cover Letter

From,
Dr.U.Tamilarasan,
Professor,
Department of Production Engineering,
Sri Sairam Engineering College, Chennai.

To
The Editor,
Journal of Materials Research and Technology

Sir,

I am submitting a manuscript for consideration of publication in Journal of Materials

Research and Technology. The manuscript is entitled “An Experimental Investigation on Surface
Roughness in the Drilling of Carbon Fiber Reinforced Aluminium (AA6061-T6) Sandwich
Composite Material using Response Surface Methodology (RSM)”.
It has not been published elsewhere and that it has not been submitted simultaneously for
publication elsewhere.
Thank you very much for your consideration.
Manuscript File Click here to view linked References

An Experimental Investigation on Surface Roughness in the Drilling

of Carbon Fiber Reinforced Aluminium (AA6061-T6) Sandwich
Composite Material using Response Surface Methodology (RSM)

U. Tamilarasan1, a, L. Karunamoorthy2, b, K. Palanikumar3, c

1
Department of Production Engineering, Sri Sairam Engineering College, Chennai-44, India.

2
Department of Mechanical Engineering, Anna University, Chennai-25, India.

3
Department of Mechanical Engineering, Sri Sai Ram Institute of Technology, Chennai-44,
India.

a
tamilarasan.u@gmail.com, bkarun@annauniv.edu, cpalanikumar_k@yahoo.com

Abstract

In the present investigation, the drilling experiments are carried out to analyse the
performance of surface roughness in drilling CFRP aluminium (6061-T6) sandwich laminates.
Aluminium (AA6061-T6) is used as a sandwich material in the fabrication of CFRP composite
laminate. In machining of fibre metal laminate, surface roughness is a very important parameter,
which has to be minimized to carry out a defect free drilling process. The three process
parameters, spindle speed, feed rate and point angle of the drill are chosen according to the
Taguchi's orthogonal array design procedure. The experimental results are analysed by using
Response Surface Methodology (RSM). The surface morphology of the machined surface is
analysed by using Scanning Electron Microscope (SEM). ANOVA is carried out to check the
adequacy of the developed model.

Keywords: Drilling, Carbon Fiber Reinforced Aluminium Sandwich (CFRP), Analysis of

Variance (ANOVA), Response Surface Methodology (RSM), Surface roughness.

1. Introduction
 Carbon Fibre Reinforced Aluminium Sandwich Composite materials are widely used in
various structural applications such as aerospace, ship building, sporting goods etc. owing to
their strength to weight ratio, corrosion resistance, light weight and high stiffness. Chongyang
Gao et al. have carried out the experiments on CFRP composite on different orientation fibre.
The cutting force increases with the increase in cutting speed for the 40° and 90° orientation and
the surface roughness decreases with the higher cutting speed, which indicates that, larger speed
is good for CFRP materials [1]. The surface modification of CFRP is conducted by using CO2
laser to remove the top resin layer. This removal of top resin layer does not affect the immediate
layer of fibre in CFRP composites [2]. To assess the quality machining of CFRP using diamond
abrasive cutters, whereas the depth of cut is found as a significant factor among the process
parameters such as feed rate, spindle speed and depth of cut [3]. The inclusion of 10-15 vol% of
carbon fibre in Si-C ceramic matrix composite improves the mechanical properties such as
fracture toughness and bending strength of the turbine blades [4]. Omanath Pawar et al. have
studied the GLARE material with an alternate thin layer of aluminium and GFRP. For both
materials, high speeds are considered with feed ranging from 0.15 to 0.3 mm/rev. The feed is a
deciding factor in controlling delamination and burr formation than the speed in machining of
GLARE [5]. To improve the hole quality in the machining of CFRP, three drill tools are
designed to evaluate the output responses such as thrust force, surface roughness, tool wear, fiber
pull-out, hole over sie and eccentricity [6]. Redouane Zitoune et al. have performed the
machining of sandwich material using tungsten carbide tool and uncoated carbide tool. When the
drill bit hits aluminium (Al) or titanium (Ti), high temperature chips are formed at the hole.
Hence, the nano coated drill tool is used to minimize the temperature, which reduces the thrust
force and roughness than that of the uncoated tool [7]. The drilling of composite/ aluminium
stack was studied by using tungsten carbide drill (K20) at high spindle speed. The thrust force of
CFRP reduces because of cutting edge temperature, which reduces the cutting resistance of
epoxy [8]. Wang et al. have performed machining process in CFRP composites. The feed rate is
the most influencing parameter, which affects the milling process and whereas roughness
increases with the increase in feed rate [9]. The drilling of sandwich material on
graphite/titanium by using HSS, HSS-CO and carbide tool is studied. The HSS and HSS-CO
drills produce the highest temperature at high spindle speed and low feed rate, which leads to
tool wear. The cutting forces, tool wear and surface roughness increase drastically at high speed
at 1750 rpm with feed 910. Sunil Hansda et al. have discussed the significance of surface
roughness and delamination of GFRP using utility concept with Taguchi's approach [11].
Thiagarajan Rajmohan et al. have analysed the machining parameters on thrust force, roughness
and burr height in the drilling of hybrid metal matrix composites. Process parameters are
optimised using RSM to minimise the thrust force, surface roughness and burr height [12]. The
dust adherence on the machined surface during high speed trimming is investigated along with
the influence of tool geometry and cutting conditions on the surface defects. The influential
parameters on the dust generated during high speed trimming are tool geometry, cutting
conditions and cutting speed [13]. The machining on FRP with vibration technique find suitable
for both precise quality hole and high-efficiency drilling process [14]. Zhi Sun et al. uses short
aramid fibre of 6 mm in length, which are more effective than long aramid fibre of 14 mm
length. The SEM image indicates that, only 6 mm aramid fibre has more resin and less bridging
gap than long pyramid fibre of 14 mm [15]. The debonding between the sandwiches does not
occur easily, since the peak load on pyramidal honeycomb is larger than that of engineering
honeycomb core [16]. Wang et al. have performed experiments on CFRP materials using milling
process with medium spindle speed, minimum feed rate and a minimum depth of cut are
preferred [17]. Optimization of the process parameters like spindle speed, feed rate, point angle
and chisel edge width in machining of GFRP Composites are studied using L9 Orthogonal array.
The most significant parameter is feed rate followed by cutting speed, chisel edge width and
point angle [18]. Shyha et al. assessed the machining parameter for the metallic composite stack.
The presence of Ti and Al on either side of CFRP laminates reduces delamination. A
microstructural deformation is occurred at the interface of Ti/Al at the hole surface due to the
heat affected zone [19]. The properties such as tensile, flexural and impact strength on CFRP are
studied and investigation is carried out using SEM images to determine the structure of the
sandwich laminates [20]. SenthilKumar et al. have assessed the tool wear on CFRP/Titanium
stacks using 100°, 118° and 130° point angle drills. The 130° point angle drill is better than 118°
point angle drill because of the smaller chisel edge thickness and increased point angle [21].
Sadek et al. have developed a model to predict the time-varying force and temperature in the
drilling of FRP. The model capability defines the effect of force and temperature around the hole
[22]. Palanikumar et al. have optimised the drilling parameters for drilling of GFRP composite
using multiple performances characteristic based on Taguchi's technique. The feed and speed
have a significant effect by using grey scale relation. The high spindle speed and low feed rate
are recommended for the machining of composite material [23]. The material defects such as
break-in and break-out are studied using CFRP composite. The effect of WC-Co and the relation
between feed and speed are established using the surface plot. A maximum amount of break-in
and break-out is obtained, when the lowest amount of feed and speed are applied [24].

The comprehensive literature study witnessed that, the surface roughness is an important
parameter in the machining of sandwich composite material for various engineering applications.
In this present investigation, the study on the surface roughness in the drilling of Carbon Fibre
Reinforced Aluminium Sandwich Composite material is carried out by using Response Surface
Methodology (RSM). The various process parameters considered are spindle speed, feed rate and
point angle. The Analysis of Variance (ANOVA) is used to determine the significance of the
process parameters on the drilling of CFRP Aluminium sandwich material.

2. Materials and Methods

The machinability of CFRP is primarily affected by the fibre and matrix properties of the
material and the drilling of composites is not a straight forward event with advanced diamond
tooling, where cutting is hampered by factors such as fibre orientation and the type of weave.
When compared to a variety of conventional workpiece materials, significantly more factors are
to be considered on machinability; due to the complexity of composite material structures and
the wide range of possible curing conditions. Defects produced when drilling FRP’s include
matrix cracking, fibre pull out and breakage, fibre/matrix debonding, thermal degradation,
delamination, fuzzing and spalling, workpiece non-homogeneity and anisotropy. Delamination
has been shown as an adequate factor, which is decreased in product bearing strength and
reduced structural integrity, with knock-on effects relating to long-term performance. When
drilling CFRP using HSS and WC drills, carbide tool produces less delamination and a reduction
in cutting force is due to lower wear rate.

Radial drilling machine of type CKP PA/30/GT having a capacity of 30 mm with 1.5
HP induction motor for spindle speed and 1 HP DC compound motor for the feed is used for
conducting the experiments. The work piece is clamped to the table or base and the drill head can
then be positioned where it is needed by swinging the arm and moving the drill head along the
arm. The Figure 1 shows the experimental setup used for conducting the experiments.

Figure 1 Experimental setup

The instrument used for the measurement of surface roughness is a Taylor Hobson
surface roughness tester with 50 mm travelling length, diamond tip stylus having a radius of 2
micron.

The specimen which is cut into 10x10 mm size for the present study and it is
subjected to Scanning Electron Microscope (SEM) analysis. They are fixed in the Karnovsky’s
fixative and then they are processed through a graded alcohol dehydration series. Then the
specimens are taken to a coating unit with ion sputter coater with a gold target. After the
completion of coating, the specimens are ready to be viewed in the SEM equipment. Images are
captured by using IRCCD camera, which is attached to the equipment.

The experimental results of surface roughness on the drilled hole has been tabulated and
presented in Table 1. Drilling of carbon fibre reinforced aluminium sandwich composite is
carried out using three different parameters namely feed rate, spindle speed and point angle, that
is made up of solid carbide with tin coated drill bit with 10 mm diameter. L27 Orthogonal Array
is followed for the design of experiment with three process parameters, 13 levels and two runs
are performed on variable drive spindle speed drilling machine. From the result, it is observed
that, the above process parameters affect the drilling of CFRP aluminium sandwich materials.
 Table 1 Experimental Results

Spindle Point Roughness factor (Ra) µm

Feed
Run speed angle
rate (f,
no. (N, (Ө,
mm/rev)
rpm) degrees) Trail 1 Trail 2 Trail 3 Average

1 450 0.04 100 1.1988 1.1882 1.1668 1.1846

2 450 0.04 118 1.2246 1.2137 1.1919 1.2101
3 450 0.04 135 1.6733 1.6585 1.6287 1.6535
4 450 0.06 100 1.6259 1.6114 1.5825 1.6066
5 450 0.06 118 1.8862 1.8694 1.8358 1.8638
6 450 0.06 135 2.5461 2.5234 2.4782 2.5159
7 450 0.08 100 2.1426 2.1236 2.0854 2.1172
8 450 0.08 118 2.8520 2.8267 2.7759 2.8182
9 450 0.08 135 3.7701 3.7366 3.6695 3.7254
10 852 0.04 100 1.1588 1.1485 1.1279 1.1451
11 852 0.04 118 1.1903 1.1797 1.1586 1.1762
12 852 0.04 135 1.5997 1.5854 1.5570 1.5807
13 852 0.06 100 1.4806 1.4674 1.4411 1.4630
14 852 0.06 118 1.7220 1.7067 1.6761 1.7016
15 852 0.06 135 2.2079 2.1882 2.1490 2.1817
16 852 0.08 100 2.0797 2.0612 2.0242 2.0550
17 852 0.08 118 2.6777 2.6538 2.6062 2.6459
18 852 0.08 135 3.3526 3.3227 3.2631 3.3128
19 1260 0.04 100 1.0141 1.0051 0.9871 1.0021
20 1260 0.04 118 1.0385 1.0293 1.0108 1.0262
21 1260 0.04 135 1.2392 1.2282 1.2061 1.2245
22 1260 0.06 100 1.2498 1.2387 1.2165 1.2350
23 1260 0.06 118 1.5254 1.5118 1.4847 1.5073
24 1260 0.06 135 1.8321 1.8158 1.7832 1.8104
25 1260 0.08 100 1.6821 1.6672 1.6373 1.6622
26 1260 0.08 118 1.9976 1.9798 1.9443 1.9739
27 1260 0.08 135 2.0424 2.0243 1.9879 2.0182

The drilling experiments are carried out on CFRP aluminium sandwich laminates
using tin coated carbide twist drill with different point angle. The machining parameters
considered are spindle speed (N) in rpm, feed rate (f) in mm/rev and point angle (θ) in degrees.
The quadratic response model is developed to predict the surface roughness on the CFRP
aluminium composite laminates.

Table 2 RSM model developed for CFRP aluminium sandwich composites

Responses Model expression R-squared

3.279 + (5.3641*10-3*N) – (96.575*f) –

Roughness (0.0435*Ө) – (0.0347*N*f) – (2.584*10-
97.23%
(Ra) in µm 5
*N*Ө) + (0.722*f*Ө) – (4.738*10-7*N2) +
(516.47*f2) + (1.71*10-4*Ө2)

The RSM model developed between the experimental value, and predicted value is
presented in Table 2. From the model, it is understood that, the predicted value is closer to the
actual value, so the developed model is effective. From the above table, it is noticed that, the R2
value is more than 95%. Hence, the model is effectively used for predicting the response to any
other value within the range of experiments.

The correlation plot for experimental value and predicted value for the output response
surface roughness is presented in Figure 2. The correlation plot between the predicted value and
the experimental value is close to each other. Hence, this model is effective. The higher value of
R2 indicates that, the model developed is well in agreement with the experimental result. Hence,
this shows the adequacy of the model, which is used for predicting the response of any other
values within the range of experiments.
 Figure 2 Correlation plots for surface roughness in the drilling of CFRP aluminium
sandwich composites

3. Results and Discussion

The surface roughness is the most important parameter in machining of CFRP

aluminium sandwich composites. The quality of the machined hole reduces the structural defects
during the manufacturing and assembly process. In drilling the CFRP composite material, the
fibre is subjected to pull out due to the stress, which is created on the various layers of the fibre
by the thrust produced on the tool. It affects the surface quality. Surface roughness is measured
by using surface roughness meter that signifies the quality of the drilled hole. The typical surface
roughness plots are recorded from the surface roughness meter (Talysurf) for the different
drilling conditions.

Figure 3 Roughness recorded on the drilled hole surface

The effect of spindle speed on the surface roughness in the drilling of CFRP composites
is presented in the Figure 4. When the spindle speed increases, the surface roughness decreases,
which is due to the reason that, the increase in the spindle speed increases the fast traverse and
heat generation. The heat generated during the drilling softens the polymer matrix in the
material, also smoothens the aluminium structure. From the analysis, it has been inferred that
high spindle speed is preferred for drilling the sandwich laminates.
Figure 4 Effect of spindle speed on surface roughness at 100° point angle in the drilling of
CFRP aluminium sandwich composites

Figure 5 Effect of Feed rate on surface roughness at speed of 450 rpm in the drilling of
CFRP aluminium sandwich composites
Figure 6 Effect of Point angle on surface roughness at 0.04 mm/rev in the drilling of CFRP
aluminium sandwich composites

The effect of feed rate on the surface roughness in the drilling of CFRP composites is
presented in the Figure 5. The surface roughness increases with the increase in feed rate, and the
reason is, due to the increase in load on the drill bit. At a higher feed rate of 0.08 mm/rev, the
rate of increase in surface roughness is very higher, when it is compared with the lower feed
rates of 0.04 and 0.06 mm/rev. It is because, when the feed rate increases, the distance travelled
by the tool into the workpiece is increased, which increases the contact area of the tool and
workpiece, which results in increased surface roughness.

The effect of point angle on the surface roughness in the drilling of CFRP composites is
presented in the Figure 6. The increase in point angle increases the surface roughness, and the
reason behind this is, due to the increase in contact area of the tool while making surface contact
with the workpiece, which in turn enhances the resistance of the material against the tool. At
higher point angle of 135°, the rate of increase in surface roughness is very higher, when it is
compared with the point angles of 100° and 118° respectively. It is because, at higher point angle
the resistance offered by the material is more, when it is compared with the lower point angles.

The ANOVA results obtained for surface response is presented in Table 3. From the
table, it is clearly seen that the model F-value is greater than the F-table value, and also the R-sq
value is greater than 97.22 %. Hence, high correlation exists between the model and the
experimental value. Further, it is found that, the developed model is well in agreement with the
experimental result, and so the developed surface response model is used for predicting the
surface roughness in the drilling of CFRP aluminium sandwich composite materials.

All the input parameters such as spindle speed, feed rate and point angle are the
significant terms, which influence the surface roughness. Out of all three parameters, the spindle
speed is the most influential parameter, as its F-value is higher than the other two parameters.
The point angle followed by feed rate is the next contributing factors for the influence of the
surface roughness.

Table 3 ANOVA for surface roughness in the drilling of CFRP aluminium sandwich
composite material

Sum of p-value
Source df Mean Square F Value
Squares Prob > F

Model 12.05073 9 1.338969 66.08226 < 0.0001

A-Spindle speed 6.838831 1 6.838831 337.5173 < 0.0001

B-Feed rate 1.512524 1 1.512524 74.64773 < 0.0001

C-Point angle 2.391164 1 2.391164 118.0113 < 0.0001

AB 0.408256 1 0.408256 20.1487 0.000323

AC 0.3688 1 0.3688 18.20143 0.000521

BC 0.276503 1 0.276503 13.64628 0.001801

 A^2 0.052252 1 0.052252 2.578818 0.126717

B^2 0.103964 1 0.103964 5.130943 0.036858

C^2 0.062286 1 0.062286 3.074019 0.097564

Error 0.344457 17 0.020262

Total 12.39518 26

R-Squared = 97.22 %

A 3-D graph for surface roughness on spindle speed and feed rate is presented in the
Figure 7. The surface plot indicates that, the low feed rate and high spindle speed are preferred in
the drilling of CFRP aluminium sandwich composite material, since at lower feed rate and higher
spindle speed, the surface roughness is minimum.

The 3-D graph for surface roughness on point angle and feed rate is presented in the
Figure 8. The surface plot indicates that, the lower feed rate and lower point angle are preferred
in the drilling of CFRP aluminium sandwich composite material, since at lower feed rate and
lower point angle, minimal surface roughness is obtained.

The 3-D graph for surface roughness on point angle and spindle speed is presented in the
Figure 9. The surface plot indicates that, the higher spindle speed and lower point angle are
preferred in the drilling of CFRP aluminium sandwich composite material, since at higher
spindle speed and lower point angle, surface roughness tends to be very minimum.
Figure 7 3-D surface interaction plot for surface roughness – AB

Figure 8 3-D surface interaction plot for surface roughness – BC

 Figure 9 3-D surface interaction plot for surface roughness – AC

The SEM images are used to observe the morphological behaviour of CFRP-aluminum
sandwich composite materials. The SEM image also provides the information of various
interfacial properties such as internal cracks, fractured surface of the composite laminates. The
specimen examined under scanning electron microscope is coated with conducting materials,
before the start of the observation of the specimen. After the process of coating, the specimens
are investigated to study about the morphological failures and surface defects of the CFRP
aluminium sandwich using Scanning Electron Microscope. The SEM micrograph of the drilled
surface of the hole for various parameters obtained for surface roughness ranging from fine, very
fine, average and course in order are presented in the Figure 10.

The Figure 10 indicates the SEM image of the drilled hole at 1260 rpm, 0.06 mm/rev and
100° point angle. The Figure 11 indicates the SEM image of CFRP top layer of the fibre of the
drilled hole. The Figure 12 indicates the SEM image of the middle layer of aluminium of the
drilled hole. The Figure 13 clearly indicates the SEM image of CFRP middle layer of the fibre of
the drilled hole. From the above figures, it is evident that, the performance of the drilling
operation for the output response (i.e. surface roughness) obtained on the point angle of 100° and
with an average feed rate of 0.06 mm/rev is 1.096 mm. The value is the lower value, when it is
compared with the drilled holes at the point angles of 118° and 135° with higher feed rates. Since
the surface contact of the tool is more in the case of 118° and 135°, the load on the tool is more,
which increases the surface roughness for the point angles 118° and 135°.

Figure 10 SEM image of the drilled hole at 1260 rpm, 0.06 mm/rev and 100° point angle
Figure 11 SEM image of the Figure 12 SEM image of the Figure 13 SEM image of the
CFRP fibre top layer of the middle layer of aluminium CFRP fibre bottom layer of
drilled hole at 1260 rpm, of the drilled hole at 1260 the drilled hole at 1260 rpm,
0.06 mm/rev and 100° point rpm, 0.06 mm/rev and 100° 0.06 mm/rev and 100° point
angle point angle angle

To check the adequacy of the developed RSM model, the confirmation experiment is
conducted. The results of the confirmation experiments are presented as the bar chart in Figure
14. The confirmation test experiments are carried out to verify the effectiveness of the
experimental result and the RSM model developed. The confirmation experiments are performed
under three different experimental conditions. Experiment no.3 with spindle speed (N), feed rate
(f) and point angle (θ). Experiment no.15 with spindle speed (N), feed rate (f) and point angle
(θ). Experiment no.26 with spindle speed (N), feed rate (f) and point angle (θ) are considered.
The results from the confirmation experiments reveal that the developed model can be
effectively used for predicting the surface roughness.
 Figure 14 Confirmation tests for Surface roughness

4. Conclusion

Machining of CFRP aluminium sandwich laminate is carried out with three different
point angles, three feed rates and three spindle speeds. Based on the experimental investigation
and analysis of the following conclusions are arrived: Surface roughness in the machining of
CFRP aluminium sandwich composites is highly influenced by feed rate followed by point angle
and spindle speed respectively. The minimum surface roughness measured is 1.0021µm. A
response surface methodology is adopted to model the output responses such as delamination at
the entry and exit regarding independently controllable variables such as spindle speed, feed rate
and point angle. The analysis of variance has indicated that the most influential parameter is
feed rate followed by the point angle and spindle speed which affects delamination at the entry
and exit of the drilled hole.

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Declaration of Competing Interest

Declaration of interests

☒The authors declare that they have no known competing financial interests or personal relationships
that could have appeared to influence the work reported in this paper.

☐The authors declare the following financial interests/personal relationships which may be considered
as potential competing interests: