Drilling of GFRP with Liquid Silicon Rubber Reinforced with fine Aluminium Powder on Hole Surface Quality and Tool Wear using DOE

The efforts are made to study the effect of machining parameters: speed, feed, tool tip angle, and tool material on hole quality: surface finish, and tool flank wear while drilling on hybrid composite laminates. The hybrid composite laminates are fabricated by making use of the compression molding technique for the optimized process parameters: Pressure 100 kgf, Temperature 50 °C and Time 40 min. Taguchi design and ANNOVA techniques for the L9 orthogonal array are used to study and optimize the machining parameters. Hybrid composite materials composed of Glass Fiber, Resin LY556, Liquid Silicon Rubber, and Fine Aluminium Powder in two different weight fractions 60:40 and 50:50 from fiber to the matrix. Due to the existing automotive materials' worse tensile qualities, the resultant material can be utilized to create automobile bumpers. The outcome shows that material with a weight fraction of 50:50 experienced reduced tool flank wear (0.04 mm). An increase in the tool-fiber contact that results from a rise in GFRP fiber concentration from 50 to 60% leads to an abrading phenomena that causes the tool to abrasively wear. The surface quality of GFRP with lower fiber content (50%) is excellent. However, in composites with a greater GFRP fiber concentration (60%) a smaller volume percentage of matrix impairs the action of covering the fiber ends. © 2023, The Author(s), under exclusive licence to Springer Nature Switzerland AG.