Abstract
Orbital drilling of composites was investigated to observe hole surface integrity in terms of surface roughness, delamination, surface burning, and geometric accuracy. Experiments were conducted with a brazed single layer diamond tool of ball-end geometry to drill 220 holes. Cutting forces and temperatures were measured. Micro-observations were made of the hole surface. The results showed that the forces increased sharply during drilling of the first 44 holes followed by a gradual rise. Part temperatures varied between 98-184°C. Surface roughness Ra varied from 13-17μm. Almost 99% of the holes were drilled without exit delamination; however, 2.3% of the holes showed entrance delamination.
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