Optimization of drilling parameters to minimize delamination in (PEKK/CFRP) thermoplastic polymer matrix composites for aerospace applications

Composite materials have revolutionized the aerospace industry since their inception in the late 1980s, with advanced composites now comprising a substantial portion of modern airframes. This paper investigates the intricate relationship between drilling parameters and delamination in polymer matrix composites, focusing on the optimization of cutting speed and feed rate to minimize damage during drilling operations. Utilizing thermoplastic matrix composite, experiments were conducted to analyze the force, momentum, and delamination factors associated with varying drilling parameters. Through statistical analysis and regression modeling, the developed delamination factor equation demonstrates strong correlation and compatibility with measured data, with an average error of 1.2%. This robust framework offers practical strategies for optimizing drilling operations and improving composite performance, contributing to the ongoing advancement of aerospace technology. This research contributes to the advancement of aerospace technology by addressing a critical aspect of composite manufacturing for thermoplastic matrices, complementing existing knowledge on thermoset composites.