A Study and Modeling of Acoustic Emission Counts in Drilling

Polymeric Nanocomposite Laminates

I.Paul T. Rajakumar1, P.Hariharan2
1

Professor, Department of Mechanical Engineering, Panimalar Institute of Technology,

Nazarathpet, Poonamallee, Chennai 600123
E-mail: paultheophilus@gmail.com

Associate Professor, Department of Manufacturing Engineering College of Engineering,

Guindy, Anna University, Chennai 600025
E-mail: hari@annauniv.edu

Abstract: Drilling is one of the frequently required machining processes in the composite
laminates owing to the need for joining structures. Machining parameters such as wt.%
Carbon Nano Fiber (CNF), spindle speed and feed rate, each with three levels were
considered for the drilling experiments in this work. The experiments were conducted as
per the full factorial design using solid carbide drill ( 6mm). Based on the experimental
results an Acoustic Emission (AE) counts prediction model was developed using multi
layer feed forward Artificial Neural Network (ANN), trained using Error Back Propagation
Training (EBPT) algorithm. The outcome of the model confirms that it can be effectively
employed for predicting the response variables while drilling carbon fiber reinforced plastic
nanocomposite laminates.
Keywords: carbon fiber reinforced plastic nanocomposite, acoustic emission counts,
drilling, solid carbide drill, artificial neural network.

1. INTRODUCTION
The carbon fiber reinforced plastic (CFRP)
composites are advanced materials employed for
many applications in aeronautical and aerospace
industries [1]. The CFRP components exhibit lower
weight, lower expansion coefficient, high strengthto-weight and stiffness-to-weight ratios, high
damping and good corrosive resistance properties
[2]. Drilling is one of the frequently required
machining processes in fiber reinforced composites
to fix fasteners for assembly of laminates. During
drilling the fiber reinforced composite materials,
delamination occurs on the exit plies which reduce
the structural integrity of the materials. In order to
minimize the effects of delamination, it is vital to
monitor the process variables and to create a
appropriate model to forecast the response variables
[3]. Many have worked in the area of monitoring
the drilling of polymeric composite laminates and
modeling the response variables by considering the
thrust force and Acoustic Emission (AE) signals.
Jin, Bao, and Gao found that while drilling CFRP
composites, bigger thrust forces lead to serious
delamination [4]. Delamination free holes can be
obtained when the drill thrust forces are less than

the critical thrust force [5,6]. Arul et.al, studied the

effect of delamination on the AE RMS while
drilling Glass Fiber Reinforced Plastic (GFRP) and
found that good correlation exists between AE
RMS and delamination factor [7,8] . Sudha,
Sampathkumar and Vijaya [9] conducted an
experimental study on drilling GFRP laminates and
found that burst type of acoustic emission is due to
delamination. Wen [10] suggested that monitoring
the thrust force while drilling CFRP composites can
be employed as on online technique for the
detection of delamination. In this work the Acoustic
Emission (AE) signals are monitored and analysed
while drilling CFRP nanocomposite laminates
using 6mm diameter soild carbide drill. The
delamination factor (Fd) is also calculated. The
main objective of the present work is to develop a
neural network model for the prediction of AE
counts which can be employed to effectively
monitor the drilling of polymeric nanocomposite
laminates.
2. EXPERIMENTAL PROCEDURE
2.1 Fabrication of Nanocomposite Laminates

In Fiber Reinforced Plastic (FRP) composite

laminates, when nano particles are mixed in the
polymer matrix, the composite may be referred as
nanocomposite or hybrid composite [11,12]. Three
different types of CFRP nanocomposite laminates
each with 0.5 wt.% CNF, 1.0 wt.% CNF and 1.5
wt.% CNF nano phased epoxy matrix were
prepared using hand lay-up method [13,14].

rate of 10 mega samples per second and the

amplitude threshold was fixed at 60dB. AE
sensor S9220 is a wideband sensor which can
monitor a frequency range of 100 KHz to 1000
KHz. The thrust force and torque were measured
with Kistler 9257B piezoelectric dynamometer.
The acoustic emission signal parameters were
measured with Physical Acoustic Corporation
(PAC, USA) PCI - 2 Acoustic Emission system

2.2 Experimental Set Up

2.3 Delamination Factor (Fd)
The three cutting parameters selected for the
present investigation are wt.% carbon nano fiber
(CNF) in the CFRP nanocomposite laminates,
spindle speed and feed. Solid carbide drill of
6mm (ADDISON) was used for drilling three
different types of nanocomposite laminates such
as CFRP nanocomposite laminates with 0.5
wt.%, CNF, 1.0 wt.% CNF and 1.5 wt.% CNF.
The machining parameters used and their levels
chosen are given in Table 1.
Table 1. Machining parameters and their levels
Machining
Parameters
CNF
contents in
the
workpiece
Spindle
speed
Feed

Level 1

Levels
Level 2

Level 3

wt.%

0.5

1.0

1.5

rpm

500

1000

1500

mm/
rev

0.02

0.05

0.08

Unit

The drilling experiments were conducted as

per the full factorial design (FFD) of
experiments. Each experimental condition was
repeated thrice and average values are tabulated.
All the drilling experiments were conducted in a
CNC machining center ARIX VMC 100. The
photograph of the experimental setup is given in
the figure 1.

Among the defects caused while drilling

polymeric nanocomposite laminates, interlaminar
delamination is a main concern. Jin, Bao, and
Gao [4] described that delamination is a
phenomenon caused by bond separation between
fiber layers because of thrust force above the
permissible
limit/threshold
value.
The
delamination severely affects the structural
integrity and reliability. The drilling induced
delamination occurs both at the entrance and exit
planes of the work piece. The delamination factor
(Fd) may be calculated from the ratio of the
maximum diameter (Dmax) of the delamination
zone to the drill diameter (D) [15].
Fd =

Dmax
D

(1)

Figure 2 shows the scheme for measuring

the delamination and this image was captured
while measuring the diameter of the delamination
zone (Dmax) using the Video Measuring System,
NIKON VMA2520.

Fig. 2 Scheme for the measurement of the

delamination [13]
Fig.1 Experimental set up
The work piece was mounted on the
dynamometer using proper fixtures and a broad
band AE sensor (S9220) was mounted on the
work piece at a distance of 50 mm from the
centre of the drilling zone for every hole drilled.
The AE signals were monitored at a sampling

The delamination occurs both at the entry

and exit side of the holes. Since the delamination
at exit is larger and affects the structural integrity
of the component than the delamination at entry,
the delamination at exit is considered for this
work and the corresponding delamination factor
at exit is calculated.

3. ARTIFICIAL NEURAL NETWORK

A multi-layer feed forward ANN, trained
using error-back propagation training algorithm
(EBPTA) was employed for the purpose of
modeling the acoustic emission counts. The
EBPTA is a supervised learning based on
generalized delta rule [16], which requires a set
of inputs and desired outputs, known as training
patterns. The ANN training primarily determines
the connection weights, which are required to
give the desired response. The initial step in
ANN model development is to build an input
output database required for training through the
drilling experiments. In order to have a complete
knowledge of drilling process over selected range
of parameters, a proper planning of
experimentation is necessary in order to reduce
the cost and time. Hence, an experimental plan
based on full factorial design (FFD) was selected
[17]. The experimental database so developed
was utilized to train multi-layer neural network
using EBPTA. The multi layer feed forward
ANN consists of neurons divided into input
layer, output layer and one or more hidden
layers. The neurons between the layers are
connected by links having synaptic weights,
which stores the knowledge regarding the input
output relationship. Figure 3 illustrate the multilayer feed forward ANN architecture employed
in the present work, which consists of three
neurons in the input layer (related to 3 process
inputs, wt.% CNF, spindle speed and feed), one
neuron in the output layer (related to one output
AE counts) and one hidden layer with 12
neurons.

Spindle
Speed

Feed

Table 2 Learning factors employed for ANN

training
Learning rate ()
Momentum constant ()
Learning rate increment ( _inc)
MSE goal
Maximum number of epochs

0.05
0.9
1.05
10-5
5000

3.2 ANN Testing

The trained ANN was initially tested by
presenting 21 input patterns which were
employed for the training purpose. Finally the
trained ANN was validated with remaining 6
trials of FFD which were not used for the
training purpose. For each input pattern, the
predicted value of AE counts is compared with
the respective experimental value. The absolute
percentage error was determined, given by
% Absolute error =

AE Counts expt AE Counts pred

AE Counts expt

100 (2)

Where AE Counts expt is the experimental

value of AE counts and AE Countspred is the
predicted value of AE counts by ANN model.

Wt.%
CNF

training simulation was carried out using variable

learning rate training procedure trainbr of
MATLAB NN toolbox. This procedure improves
the performance of EBPTA by allowing learning
rate to change based on complexity of local error
surface. The ANN training is highly sensitive to
number of neurons used in the hidden layer.
However, the number of hidden layer neurons
required for successful ANN training is problem
dependent and is usually determined by trial and
error procedure. Table 2 presents all the learning
factors employed in the present investigation.

AE
Count
s

12

Fig.3 Multi layered feed forward ANN

architecture
3.1 ANN Training
The ANN training was performed using first
21 inputoutput patterns from the experimental
database, while the last 6 data were employed for
ANN testing. The training of ANN for these 21
input output patterns has been carried out using
NN tool box of MATLAB software. The ANN

4. RESULTS AND DISCUSSION

During drilling of composite laminates, the
material is removed with a wedge shaped drill
causing a series of fracture. This is associated
with plastic deformation and cracking in the
work material ahead of the cutting wedge and
sliding at high stress and strain rates resulting in
the rapid release of energy termed as acoustic
emission. The AE count is the number of times
the signal amplitude exceeds the preset reference
threshold. A single acoustic emission event can
produce several counts. A larger event requires
more cycles to ring down to the trigger level and
will produce more counts than smaller event.
This provides a measure of intensity of the
acoustic emission event. The counts are widely
used as a practical measure of acoustic emission

activity. Figure 4 is a typical AE counts vs time

graph monitored while drilling the CFRP
nanocomposite with 0.5wt.% CNF at a feed 0.02
mm/rev, spindle speed 500 rpm and it clearly
shows the AE counts of the hits monitored from
the drill entry till the drill exit.

increases. The increase in counts indicate the

increase in AE activity at the source. Therefore,
large counts monitored while drilling CFRP
nanocomposite laminates with 0.5wt.% CNF may
be attributed to increase in energy release owing to
larger delamination factor at exit. The lower counts
monitored while drilling CFRP nanocomposite
laminates with 1.5wt.% CNF may be attributed to
the decrease in energy release due to the smaller
delamination. From the experimental results it is
inferred that good correlation exists between AE
counts and delamination factor at exit as shown in
the figure 5. Hence, modeling of AE count can help
in the prediction of delamination factor at exit and
thereby defect free drilling of CFRP nanocomposite
laminates can be achieved.
The developed ANN model was trained and
then tested. The ANN predicted values for AE
Counts are found to be very close with the
experimental values for all the 21 training
experiments as illustrated in figure 6. From the
figure 7, it can be seen that the maximum
absolute error was found to be 2.81% for the
training experiment

Fig. 4 A typical AE Counts vs Time graph

The sudden release of the drill at the exit of
the hole results in delamination at the exit ply of
the hole contributing to the maximum AE counts
at the exit of the hole as shown in figure 4. The
AE count is higher while drilling CFRP
nanocomposite laminates with 0.5 wt.% CNF and
AE count is lower while drilling CFRP
nanocomposite laminates with 1.5 wt.% CNF as
shown in figure 5.

Fig.6 Comparison of the ANN predicted and the

experimental values of AE counts for the training
experiments

Fig. 5 AE Counts vs Delamination factor at exit

The reason may be due to the fact that the AE
counts to peak is higher while drilling CFRP
nanocomposite laminates with 0.5 wt.% CNF and
counts to peak is lower while drilling CFRP
nanocomposite laminates with 1.5 wt.% CNF.
When the count to peak increases, the count also

Fig.7 Error profile of AE counts for the

training patterns

The trained ANN was tested with remaining

6 trials of FFD which were not used for the
training purpose. The comparison of the
predicted and the experimental values of AE
count for the validation data set is presented in
figure 8. From the test results, it is clearly
observed that the predicted values are very close
and follow almost the same trend as the
experimental values. Figure 9 illustrates the error
profile of AE counts for testing experiments from
which it can be seen that the maximum absolute
error was found to be 6.1%.

5. CONCLUSION
Experiments were conducted with three
factors (wt.% CNF, spindle speed and feed) each
with three levels as per full factorial design of
experiments in order to monitor the drilling of
CFRP nanocomposite laminates using acoustic
emission. Based on the results of experiments an
AE counts prediction model was developed using
multi layer feed forward ANN, trained using
EBPT algorithm. Based on the experimentation
and the analysis the following conclusions are
drawn.

AE count is sensitive to the process

damage such as delamination. Therefore
by monitoring AE counts during the
drilling of CFRP nanocomposite
laminates,
delamination
can
be
effectively controlled.

The delamination factor at exit and AE

count decreases with increase in wt.%
CNF
in the matrix of the
nanocomposite laminates ranging from
0.5 wt.% CNF to 1.5 wt.% CNF
indicating that better holes can be
drilled in the CFRP nanocomposite
laminates with higher wt.% CNF in the
matrix.

The predicted AE counts values and

measured AE counts values are
reasonably close to each other, which
signify that the developed ANN model
can be successfully used to forecast the
AE counts while drilling the CFRP
nanocomposite laminates

The developed neural network model

shows a good correlation both for
training and testing data sets, thus
validating the model.

Fig.8 Comparison of the ANN predicted and the

experimental values of AE counts for the testing
experiments

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perfect correlation between targets and outputs.
In the present case, the R value is 0.9899 for the
training patterns and 0.9648 for the testing data,
which indicates a good correlation.

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