Optimization of <scp>AWJ</scp> parameters for improved material removal and hole geometry in drilling of <scp>Glass Fiber</scp>/<scp>A</scp>luminum mesh epoxy hybrid composites

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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.

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

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Abrasive waterjet cutting of r‐GO infused magnesium fiber metal laminates: Experimental investigations and optimization through gorilla troops algorithm

Siva Kumar,

Rajamani

2024

Laminated metal‐composite structures, known as fiber metal laminates (FMLs), are modern lightweight materials extensively utilized in diverse industries such as aerospace and automotive manufacturing. These materials offer enhanced impact and fatigue resistance, making them invaluable for various applications. However, machining FMLs poses a challenge due to the occurrence of delamination and heterogenous in nature during conventional methods. Therefore, this study aims to investigate the quality characteristics such as kerf width, surface roughness and kerf taper of Magnesium based FMLs processed with an unconventional machining process namely abrasive water jet cutting (AWJC). These FMLs comprise alternately stacked kevlar/carbon fibers adhesively bonded with epoxy resin matrix filled with varying wt% of reduced graphene oxide (r‐GO), combined with AZ31B alloy sheet as the skin material. AWJC experiments were performed by varying the process parameters including waterjet pressure (275–325 MPa), stand‐off distance (2.5–3.5 mm), and cutting speed (600–800 mm/min) based on the box–behnken experimental design. The findings from the statistical analysis underscore the significant influences of stand‐off distance and waterjet pressure on kerf characteristics, while the inclusion of r‐GO is observed to notably affect the surface quality. In pursuit of enhancing cut quality, a multi‐response optimization was conducted employing the Gorilla Troops Optimization (GTO) algorithm. Comparative analysis with established metaheuristics like the gray wolf algorithm, dragonfly algorithm, and harmony search algorithm reveals GTO's superior performance across various metrics, including rapid convergence, diversity, and spacing values. Further, the cutting‐induced damages such as matrix plowing, fiber‐metal debonding and composite delamination were observed through microstructure analysis.Highlights Magnesium (AZ31B) fiber metal laminate comprising with various wt% of reduced graphene oxide was fabricated. Abrasive waterjet cutting of FMLs were performed based on box–behnken design experimental approach. Statistical analysis and influence of process parameters on the kerf width, surface roughness and kerf taper were investigated. Multi‐response optimization was carried out using metaheuristic‐based gorilla troops algorithm.

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.