Control and optimization of machining processes are important issues affecting the development of productivity. Monitoring systems have become indispensable in the evaluation of materials during machining. In this paper, the path toward the delamination-free drilling of glass/epoxy composite material is established using some novel methods based on acoustic emission features. Acoustic emission monitoring with three techniques, sentry function, acoustic emission energy distribution, and acoustic emission count distribution, are developed to detect and realize the critical force at the onset of delamination process on glass/epoxy composite materials. The three-point bending test simulates thrust force, the most effective factor in delamination, throughout the process of drilling without backup plate. Sentry function is regarded as a new method based on the combination of AE information and mechanical behavior of composite materials. The sentry function was used to study the initiation and growth of delamination process. Two types of specimen with different layups, woven [0, 90]s and unidirectional [0]s, leading to different levels of damage evolution, were studied. Results show that AE parameters and sentry function method are useful tools for the examination of initiation and the growth of delamination during drilling process and can help to avoid delamination damage while drilling.
