Table of Contents
Indian Journal of Materials Science
Volume 2016 (2016), Article ID 9380583, 8 pages
Research Article

Detecting Safety Zone Drill Process Parameters for Uncoated HSS Twist Drill in Machining GFRP Composites by Integrating Wear Rate and Wear Transition Mapping

1Department of Mechanical and Manufacturing Engineering, Manipal Institute of Technology, Manipal University, Manipal 576104, India
2Department of Humanities and Management, Manipal Institute of Technology, Manipal University, Manipal 576104, India

Received 4 March 2016; Revised 18 May 2016; Accepted 13 June 2016

Academic Editor: Pradeep Lancy Menezes

Copyright © 2016 Sathish Rao Udupi and Lewlyn Lester Raj Rodrigues. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.


The previous research investigations informed that the tool wear of any machining operation could be minimized by controlling the machining factors such as speed, feed, geometry, and type of cutting tool. Hence the present research paper aims at controlling the process parameters to minimize the drill tool wear, during the machining of Glass Fiber Reinforced Polymer (GFRP) composites. Experiments were carried out to find the tool wear rate and a wear mechanism map of uncoated High Speed Steel (HSS) drill of 10 mm diameter was developed for the drilling of GFRP composite laminates. The surface micrograph images on the drill land surface displayed dominant wear mechanisms induced on HSS drill during machining of GFRP and they were found to be adhesive wear, adhesive and abrasive wear, abrasive wear, and diffusion and fatigue wear. A “safety wear zone” was identified on the wear mechanism map, where the minimum tool wear of the HSS drill occurs. From the safety zone boundaries, it was inferred that the drill spindle speed should be set between 1200 and 1590 rpm and feed rate must be set within a range of 0.10–0.16 mm/rev for GFRP work and HSS tool combination to enhance the service life of 10 mm HSS drills and to minimize the tool wear.