Materials Today: Proceedings 56 (2022) 2690–2695

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Delamination evaluation in drilling of composite materials – A review

Punit Patel ⇑, Vijay Chaudhary
Department of Mechanical Engineering, CSPIT, Charotar University of Science and Technology (CHARUSAT), CHARUSAT Campus, Changa 388421, India

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

Article history: The persisting challenge for adaptable composite material, to make a remarkable material property along
Available online 8 October 2021 with lighter and stiffer parts. This leads to a wider application of composite materials (CFRPs and GFRPs)
due to its better adaptability and predominant properties. Mechanical drilling is inevitable mode of oper-
Keywords: ation and it’s always challenging and difficult for CFRP which leads to various onset damages. Drilling
Composite material originated delamination at entry and exit of hole is most undesirable and defying damage leads to mate-
Drilling rial rejection. Delamination assessment is always important for correction and improvement of assemble
Delamination
parts to achieve highest performance index. During last few decades, various delamination factors have
Delamination assessment
Delamination measurement
been derived and suggested as a point of reference for delamination measurement and meanwhile var-
ious delamination assessment techniques are being proposed to measure the severity of delaminated
zone for evaluation of delamination. This state-of-art review paper summarizes various delamination
quantification and measurement techniques for the correction and improvement of drilling approach
reported in open literature. It can be referenced not only as an up-to date summary available form past
results but also possibilities for future scope to subdue delamination during drilling in CFRP.
Copyright Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 3rd International Con-
ference on Contemporary Advances in Mechanical Engineering

1. Introduction ling originated delamination is most acute and challenging damage

For design and manufacturing of various engineering applica-
tions, a wide range of materials are available and selection may
start from ancient materials to recently developed composite
materials [1,2]. In last few decades, Composite materials are the
most incredible and adaptable engineering materials because of
its dramatic heterogeneity in strength from one domain area to
another which do not exhibit plastic deformation as well signifi-
cantly high strength to weight ratio [3–5]. As a consequence of
these remarkable benefits, the composite laminates are extensively
used in numerous aerospace, defense, marine, sporting goods and
transportation applications [6]. Despite the fact that composite
parts are regularly made close to net shape, some machining activ-
ities are regularly crucial to bring the machined parts into dimen-
sional necessities for perfect assembly [7]. Drilling is fundamental
operation in making precise and high-quality holes for various per-
manent and semi-permanent joints during final assembly of a
complex products made from composite laminates. Delamination
is a major unusual damage evolved during drilling operation. Dril-
which may lead to heavy losses in terms of material and cost dur-
ing final assembly. It is observed that drilling originated delamina-
tion occurs if the drilling thrust force is higher than the critical
thrust force. However, reduction in thrust force depends upon tool
geometry, drilling condition and non-conventional drilling meth-
ods [8–10]. It means drilling induced delamination can be sup-
pressed by using optimization in drill design (cutting angle and
tool geometry), optimization in drilling parameters and conditions
(feed, speed and different drilling strategies) and efficient drilling
methods [1]. Various researchers have proved that innovative drill
geometry, low feed rate and high cutting speed favor delamination
free hole during drilling operation. But it was reported that, 40%
machining time is devoted to drilling operation for assembly of air-
plane and by the reason of drilling induced delamination more
than 55% parts are rejected during final assembly [11]. Therefore,
delamination measurement and assessment has attracted substan-
tial research effort in past few decades.
2. Delamination mechanics illustrations

⇑ Corresponding author. According to formation mechanism of delamination, delamina-

E-mail address: punitpatel.me@charusat.ac.in (P. Patel). tion at hole entry is generally known as peel-up (or infeed side)

https://doi.org/10.1016/j.matpr.2021.09.267
2214-7853/Copyright Ó 2021 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 3rd International Conference on Contemporary Advances in Mechanical Engineering
P. Patel and V. Chaudhary Materials Today: Proceedings 56 (2022) 2690–2695

delamination whereas, delamination at hole exit is usually noted 60% of parts may be rejected because of delamination originated
as push-out (or hole exit) delamination. Peel-up (or infeed side) damages during final assembly of an aviation vehicle [15,16].
delamination is associated with the combined action of drilling
torque, shape of the flute and helix angle. Because of the drill vibra-
3. Delamination measurement
tion, the fibers associated to the top layer are not cut sufficiently.
Fiber borders are being pulled up and cause delamination accord-
The measurement of drilling originated delamination is always
ing to mode I in terms of opening cracks. In addition, the first ply
become a great importance for many researchers to evaluate the
being up the flutes of the drill close to the gesture of a corkscrew
numerical values of delamination. An up-to-date summaries of dif-
separates the first ply of the material with other laminates and cre-
ferent quantification methods employed by various researchers is
ates a delaminated area due to tearing shear effect under Mode III
mentioned in sub-section. The quantification methods can be sim-
loading. Whereas, Push-out (or hole exit) delamination is greatly
plified as Conventional delamination factor (Fd), adjusted delami-
associated with macro-mechanical behaviour of laminate, thrust
nation factor (Fda), delamination factor (Fd), An equivalent
force and drilling setup. As the drill tool reaches towards the
delamination factor (FD), equivalent delamination factor (Fed),
end, the uncut thickness of laminate becomes smaller and the
Extension of the Adjusted Delamination Factor (SFDSR), three-
restriction to deformation decreases. The axial thrust force of the
dimensional delamination factor (Fv) as tabulated in (Table 1).
drill is sufficient to tear interlayers of composite materials and
allows to generate a damaged area as tool exits the part. Due to
axial force through drill and bending through bottom pile, the frac- 3.1. Conventional delamination factor (Fd)
ture takes place by mode I and mode II. Fig. 1 represents mecha-
nism of delamination during drilling of composite laminate Due to the simplicity of the computing parameters for the
[1,7,8,10,12–14]. In a various study, it was observed that about researchers, Chen [17] had proposed a very basic and conventional

Fig. 1. Delamination Mechanics; (a) Peel-up delamination, (b) Push-out delamination [1,7,8,10,12–14].

Table 1
Delamination measurement available in open literature.

Delamination quantification Mathematical formula Ref.

Conventional delamination factor (Fd) F d ¼ DDmax
0
Chen [17], Gaitonde et al. [18], Schuhmacher et al. [19],
Rubio et al. [20]
Adjusted delamination factor (Fda) F da ¼ a DDmax þ b AAmax Rubio et al.[20], Davim et al [21]
0 0


F da ¼ F d þ AmaxAdA0 F 2d  F d
Delamination factor (Fd) F d ¼ AAmax Chaudhary et al. [22], Bajpai et al. [23],Patel et al. [24]

hole 
An equivalent delamination factor (FD) FD ¼ AdelAA nom
% Faraz et al. [25]
nom
pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
Equivalent delamination factor (Fed) De ðp4ðAd þA0 ÞÞ Tsao et al. [26]
F ed ¼ D ¼ D


Extension of the Adjusted Delamination Factor (SFDSR) SFDSR ¼ a Dmax
þ b AAmax Adcs
þ 2 AðdcsÞmax Sobri et al. [27]
D0 0 Ac0
Minimum delamination factor (Fdmin) Fdmin ¼ DDmin
0
Da Silva [28]
Three-dimensional delamination factor (Fv) Pp Akd Xu et al.[29]
F v ¼ VVnom
d
¼ 1p k¼1 Ahole

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P. Patel and V. Chaudhary
delamination factor. It is the ratio of maximum diameter of the
delamination zone to the nominal diameter of the hole when these
two circles are concentric as shown in Fig. 2. The conventional
delamination factor provides satisfactory results when the delam-
inated damage is in regular pattern but when delamination avail-
able in irregular pattern along with cracks and breaks. Fd might
not be an accurate selection for computing delamination
numerically.
3.2. Adjusted delamination factor (Fda)
Delamination present in CFRP material is always in irregular
pattern having cracks and breaks, so conventional delamination
factor is not appropriate due to damage area contribution is
neglected. To overcome the limitations, Davim et al [16] devised
a novel approach, namely as adjusted delamination factor (Fda).
This factor includes two parts, the first part deals with contribution
of crack size, whereas the second part involves contribution of
damaged area. The adjusted delamination factor (Fda) seems to
be more accurate compare to the previous delamination factor
but it may not be very accurate when there is a very fine crack.
3.3. Delamination factor (Fd)
Chaudhary et al. [22] proposed delamination factor (Fd) to
include the damage area which is completely ignored in one
dimensional delamination factor. It is the ratio of maximum
delaminated area to the nominal area of a hole. Delamination fac-
tor (Fd) seems prominent due to the whole effect of damage area
involved but it is still inaccurate for an irregular patten along with
long cracks.
3.4. Equivalent delamination factor (FD)
Faraz et al [25] used an equivalent delamination factor (FD) in
his study for measurement of delamination at entry and exit of
hole. It is defined as a ratio of difference between delaminated area
and nominal area of hole to the nominal area of hole. This factor
possesses same limitations as Delamination factor (Fd) but it seems
accurate compare to the one-dimension delamination factor.
Fig. 2. Schematic representation of delamination damage.
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Materials Today: Proceedings 56 (2022) 2690–2695
3.5. Equivalent delamination factor (Fed)
Tsao et al, [26] suggested an unconventional equation to char-
acterize the delamination factor namely as Equivalent delamina-
tion factor (Fed). This factor deals with equivalent delamination
diameter (De) and nominal diameter (D). Equivalent delamination
factor (Fed) obtains better results compare to other quantification
methods but it is still unclear about the contribution of damaged
area which is actively incorporated.
3.6. Extension of the adjusted delamination factor (SFDSR)
For more efficient delamination quantification, Sobri et al, [27]
suggested an unusual approach to measure the delaminated zone,
as Extension of the Adjusted Delamination Factor (SFDSR). This fac-
tor involves three parts, the first part involves influence of crack
contribution, the second part involves damage area contribution
and the third part deals with internal surface area contribution.
It is still unclear about the effect of very minor crack on the delam-
ination factor.
3.7. Minimum delamination factor (Fdmin)
To conquer the restriction of the Conventional delamination
factor (Fd), De Silva [28] proposed a minimum delamination factor
(Fdmin). It is the ratio between minimum diameter of damage zone
(Dmin) and hole diameter (D0). The formulation of Minimum
delamination factor (Fdmin) depends on the evaluation of minimum
damage zone and gives a better results associated to the delamina-
tion factor. Minimum delamination factor (Fdmin) provides very
close results to the conventional delamination factor when delam-
ination in regular pattern whereas in irregular pattern, this factor
eliminates the effect of concentricity for two circles and improved
results for irregular pattern.
3.8. Three-dimensional delamination factor (Fv)
The mentioned before delamination factors are either one-
dimension or two-dimension delamination factors, which are
bounded up to the in-plane delamination quantification. With
the help of advanced non-destructive techniques, delaminated
area inside the composite layers can be measured easily. Xu et al,
[29] proposed the three-dimensional delamination factor (Fv) to
quantify out-of-plane delamination very meticulously. The three-
dimensional delamination factor (Fv) is represented as a ratio of
the cumulative volume (Vd) of the delaminated layers to the nom-
inal hole volume (Vnom) of the layers irrespective to the composite
thickness. This factor is a cumulative addition of delaminated area
of each layer hence it does not include the maximum crack length
as a limitation of two-dimension delamination factor.
4. Delamination assessment
In order to obtain the information related to size, shape and
behavior of delamination, various non-destructive methods are
employed by various researchers in past few years. The assessment
employed by any researchers is integration of image capturing and
image processing. According to the science used behind data acqui-
sition for image of the specimen, various image acquisition meth-
ods like ultrasonic C-Scan, microscopy, X-Ray radiography and
computed tomography, Infrared Thermography, shadow moiré
laser-based imaging technique, Eddy current, thermography, Digi-
tal scanning or radiography are used by various researchers and as
tabulated in (Table 2).
P. Patel and V. Chaudhary
Table 2
The most-used delamination assessment methods available in open literature.
Assessment approach Obtained results
Ultrasonic C-Scan
Microscopy
X-Ray radiography and computed tomography
Infrared Thermography
Shadow moiré laser-based imaging technique
Eddy current
Digital scanning/radiography
4.1. Ultrasonic C-Scan
Tsao et al, [26] employed high frequency ultrasonic C-Scan, most
widespread non-destructive technique, to examine the defects
inside CFRP specimen. They used sound energy at 5 MHz frequency
in a pulse-echo mode by means of a focused broadband transducer.
Similar technique was used by Tsao et al. [30–32], Haegeret et al.
[33], Kersemans et al. [36] for image acquisition of delaminated
zone in carbon/epoxy composite material. Recently, Xu et al. [29]
characterized interlaminar delamination using a high-frequency
scanning acoustic microscope (SAM) at a frequency of 140 MHz,
which promises detection accuracy of less than 1 mm. Although
the influence on various mechanical properties of the specimen
due to absorption of liquid during measurement is still unclear.
4.2. Microscopy
Due to its simplicity and reliability, visual inspection using low
magnification microscopy technique is most commonly used in
industrial practice for quality assurance. Various researches
[33,37–42] have performed vast number of experiments for quali-
fication of delaminated zone using microscopy technique. The
acquired images from microscope are then processed using various
image processing software like, ImageJ, AnalySIS etc. This software
is generally work on pixel count method to quantify the delami-
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Materials Today: Proceedings 56 (2022) 2690–2695
Research papers available
Tsao et al, [26,30–32], Xu et al, [29], Haeger et al. [33], Stefaniuk et al. [34],
Ng et al. [35], Kersemans et al. [36], Durao et al. [41]
Faraz et al. [25], Davim et al. [21,37], Haeger et al. [33], Caprino et al [38],
Gaitonde et al [39], Patel et al [40] Debnath et al. [41–42]
Chen [17], Tsao et al. [31], Haeger et al. [33], Durao et al. [43], Hochang et al.
[44], Lopez-Arraiza et al. [45], Saoudi et al. [46], Trappe et al. [47]
Kersemans et al. [36], Bai et al. [48], Suriani et al. [49]
Seif et al. [50]
Mook et al. [51]
Davim et al. [21], Durao et al. [43,52], Khashaba [53], Nagarajan et al [54],
Silva et al. [55], De Albuquerque et al. [56]
nated area of the specimen. However, it is still challenging to
obtain the accurate measurement of hidden delamination due to
low magnification factor and resolution limit using this method.
4.3. X-ray radiography and computerized tomography (CT)
Now a days, X-ray radiography and computerized tomography
(CT) is extensively used non-destructive method in industry. X-
ray radiography successfully exhibits the interior defects of com-
posite products and CT displays three dimensional views of tiny
imperfections (pores, voids, cracks, etc.). Chen [17] and Tsao
et al. [31] used this method to measure delamination of drilled
specimen very accurately. Hence, this NDT method seems practica-
ble and efficient as well for the assessment of drilling originated
delamination but due to high initial cost, secured area for inspec-
tion, sample preparation time reduce its popularity in industry.
4.4. Thermography
Bai et al. [48] used Thermographic non-destructive testing
(NDT) which works on electromagnetic waves to evaluate subsur-
face defects in carbon fiber composite material. This method shows
prominent results even for a large surface area despite of the defect
is located just few millimeters below the surface of specimen.
Kersemans et al. [36] concluded in his research paper that lock -
P. Patel and V. Chaudhary
in thermography is very effective NDT technique over pulse ther-
mography with the advantages in terms of sensitivity and accu-
racy. However, thermography technique does not reveal its
accuracy for very thin and curved specimen.
4.5. Shadow moiré laser-based imaging technique
Seif et al. [50] invented, a unique non- contact non-destructive
technique named as, shadow moiré laser-based imaging technique
for measuring and computing the extent of hidden delaminated
damage in carbon composites materials. This technique is easily
adaptable and shows promising advantages in terms of simplicity
and accuracy. The effect of different machining parameters on dis-
tinct composite material is still unclear and hence more laboratory
scanning are needed.
4.6. Eddy current
Mook et al. [51] proposed eddy current method for non-
destructive testing of CFRP specimen. This novel approach recon-
structs current distribution in specimen from the magnetic field.
Delamination between differently oriented laminates can be eval-
uated using this method but behavior of inter-fiber and inter-
laminar current is still unclear.
5. Conclusion
This article summaries well enough of delamination measure-
ment and assessment for delaminated zone in drilling of composite
materials. The following conclusions are extracted from detailed
review;
 Delamination is reasonably connected to the critical thrust force
and below critical thrust force no delamination occurs.
 One dimensional delamination factor is quite easy to calculate
but does not include overall damage area contribution. Thus,
it doesn’t compute the accurate delamination factor.
 Various authors have developed numerous two-dimensional
delamination factor considering various possibilities but these
factors exclude straightforwardly the foot-print of crank length
contribution on overall delamination factor.
 Adjusted delamination factor optimally considers crack length
and delaminated area contribution but adjusted delamination
factor seems inaccurate when the damage area is minimal,
whereas the extension of the adjusted delamination factor
(SFDSR) seems quite prominent to calculate delamination factor
because it includes internal surface area contribution along
with rack length and damage area contribution.
 Three-dimensional delamination factor appears noteworthy for
the calculation of delamination factor irrespective of composite
thickness but computation time is higher compare to other
techniques.
 Delamination factor value differs as the method changes and
many permutations and combinations are possible to define a
more accurate delamination factor.
 Various delamination measurement methods along with their
advantages and drawbacks have been compared and discussed.
X-ray radiography and computerized tomography (CT) is more
accurate but due to high initial cost, secured area for inspection,
sample preparation time reduce its popularity in industry.
 Microscopy is commonly used method because of its simplicity
but it is still a challenge to measure an accurate delaminated
zone. Whereas ultrasonic C-scan is highly meticulous for detec-
tion of inner delamination but more studies on reflection nature
of ultrasound waves should be conducted.
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CRediT authorship contribution statement
Punit Patel: Formal analysis, Investigation, Validation, Visual-
ization, Writing – original draft. Vijay Chaudhary: Supervision,
Writing – review & editing.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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