Hole quality evaluation for abrasive water jet drilling of GF /Al mesh reinforced epoxy hybrid composites

Self Cite

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.

Optimization of AWJ parameters for improved material removal and hole geometry in drilling of Glass Fiber/Aluminum mesh epoxy hybrid composites

Seif,

Fathy,

El Aal

et al. 2024

Self Cite

Bearing strength performance: A study on the influence of AWJ drilling and delamination of GF/Al‐mesh reinforced polymer composites

Alansari,

Seif,

Fathy

et al. 2024

Self Cite

Fiber‐reinforced composites acquire widespread use in the technologically advanced sectors on account of their lightweight and outstanding strength. Considering the significant connection between component quality and durability, bearing strength is a critical factor in the mechanically assembled parts during the manufacturing process. Therefore, in this paper, an experimental study was performed on hybrid glass fiber/aluminum‐mesh composites to assess the impact of abrasive water jet (AWJ) drilling on delamination and bearing strength. The samples were drilled, and the delamination damage was assessed. Finally, the bearing test was conducted on the sample in conformity with ASTM D5961M. The impact of stress distribution on the specimen's failure patterns was studied. Experimental outcomes reveal that the GFA specimen had a 2.9% higher average bearing strength than the AGF specimen. The drilling‐induced damage was determined to be the primary factor responsible for a 27% reduction in bearing strength. The optimization of operational parameters yields improved bearing load and lower damage. A significant level of conformity was detected by the regression accuracy and validation test results with a residual error of less than 10%.Highlights A comparison of two hybrid composites utilizing various layouts for damage and load bearing. Delamination damage is a key factor in predicting the efficiency of bolted connections. Using optimized operation parameters enhances drilling output response significantly.

Geometry accuracy control in abrasive water jet taper hole machining of ultra‐thick carbon fiber‐reinforced polymer (CFRP) laminates

Liang,

Cheng,

Dong

et al. 2024

The primary factors affecting the geometric accuracy of abrasive water jet (AWJ) machining of ultra‐thick carbon fiber‐reinforced polymer (CFRP) laminates are the cutting front drag and kerf width deviation caused by energy dissipation. Firstly, this study comprehensively analyzes the influence of the coupling relationship between cutting front drag and kerf width deviation on the geometric accuracy of hole machining. Secondly, a gradient distribution theory for jet traverse speed with cutting depth is proposed for taper hole machining characteristics. Finally, a general geometric error model applicable to both straight and taper hole machining of ultra‐thick CFRP laminates using AWJ is established, along with a geometric error compensation method. A series of experiments validate the accuracy of the proposed geometric error model and compensation method. The novelty of this research lies in unifying the geometric error models for straight and taper hole machining of ultra‐thick CFRP laminates by considering the gradient distribution of jet traverse speed. The proposed error compensation method reduces the high degree of freedom required for machine tools. This study provides a general geometric error model and compensation strategy for AWJ hole machining of ultra‐thick CFRP laminates, which has significant engineering value for achieving 3D controllable AWJ machining of complex ultra‐thick CFRP components.Highlights The high geometric precision taper holes machining technique is a necessary prerequisite for achieving precise machining of complex trajectories in ultra‐thick CFRP with abrasive water jet. The influence of the coupling relationship between cutting front drag and kerf taper on the geometric accuracy of hole processing is comprehensively analyzed. A model considering the gradient distribution of traverse speed during taper holes machining was established, and a geometric error model considering this gradient distribution of traverse speed was developed. A taper holes machining geometric error compensation method with high engineering applicability was proposed. Geometric error prediction experiments and error compensation experiments were conducted, and the results proved the accuracy of the geometric error model and error compensation method.