Comprehensive Study on Tool Wear During Machining of Fibre-Reinforced Polymeric Composites

The use of fibre 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.