article · Polymer Composites
Abrasive waterjet drilling was examined across three configurations of glass fibre and aluminium mesh epoxy hybrid composites: neat glass, exterior aluminium, and interior aluminium. The drilling trials evaluated how jet pressure, standoff distance, and traverse speed influence material removal rate, hole taper ratio, and roundness error. Using a Taguchi experimental design, traverse speed and standoff distance proved to be the dominant factors controlling hole taper and roundness errors. Maximum material removal occurred at 150 MPa pressure, 2 mm standoff distance, and 900 mm/min traverse speed. Simultaneous optimisation via Grey relational analysis identified 150 MPa, 2 mm, and 300 mm/min as optimal for overall hole quality and cutting rate. Experimental validation confirmed these settings, and a multiple regression model was formulated to predict drilling performance.
Drilling hybrid composites composed of polymer fibres and metal mesh frequently introduces geometric flaws such as tapering and out-of-round holes. Identifying the correct machining parameters for abrasive waterjets enables cleaner cuts and higher drilling efficiency. This knowledge assists manufacturing engineers in maintaining structural integrity and tight tolerances when assembling complex composite components.
This research is relevant to precision machining facilities and composite fabricators working with hybrid glass-fibre and metal laminates. Production engineers can utilise the optimal parameter thresholds and predictive regression model to reduce trial-and-error setup times on the shop floor. The findings represent applied, experimentally tested research that establishes operational machining guidelines, remaining a step away from automated commercial software integration.
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Abstract This study explores the application of abrasive waterjet drilling (AWJD) for varied patterns of GF/Al mesh hybrid composites (neat glass NG, AG: Al in the exterior surface, and GA: Al in the center). Key parameters such as jet pressure ( P ), standoff distance ( S ), and traverse speed ( V ) are systematically varied, influencing material removal rate (MRR), hole taper ratio (), and roundness error (). Employing a Taguchi approach with an L9 design. It was indicated that the optimal conditions for maximum MRR are ( P : 150 MPa, S : 2 mm, and V : 900 mm/min). V and S are the main influential parameters on and . Gray relational analysis (GRA) is employed for simultaneous optimization, enhancing drilling performance. The optimal parameters P of 150 MPa, S of 2 mm, and V of 300 mm/min are determined. Validation trials confirm the effectiveness of the determined parameters. A robust multiple regression equation is formulated, providing a predictive model that aligns closely with experimental observations. Highlights The hybrid composites were drilled via a nontraditional process. The attributes of the hole geometry and the material removal impacts were studied. Operation parameters were optimized to improve MRR, , and . A multiple regression model and a confirmation test were performed and validated.
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DOI: 10.1002/pc.28224
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