Impact of process parameters in drilling of glass epoxy composite with clam shell and cenosphere filler: A comparative analysis

Abstract

Drilling is one of the secondary machining techniques most frequently utilised when Glass Fibre Reinforced Polymer (GFRP) materials are assembled into a structure. The present work examines the drilling GFRPs and analyses hole quality based on the different traditional parameters: feed rate, spindle speed, and drill tool diameter. However, the hybridization of glass fiber- reinforced polymers (GRPs) by incorporating fillers as secondary reinforcement in the present piece of research has introduced new challenges for hole drilling and achieving the desired surface finishes. The delamination at the hole entrance and exit, considering the drill diameter of the HSS twist drill (6, 8, 10 mm), feed rate (0.04, 0.08, 0.12 mm/rev), cutting speed (1000, 1200, 1400 rpm), and filler content (0, 10, 20 wt.%) in GFRP, are the major factors are considered. The fillers used are clamshell powder and cenosphere, which are marine waste and thermal power plant waste, respectively. The present paper aims to study the effect of these fillers on the drilling-induced damages to the holes in terms of delamination factor, surface roughness, and dimensional accuracy of the hole (taper error, circularity error) of GFRPs. The most widely preferred Taguchi experimental design has been used for optimising the process parameters to obtain minimum delamination, surface roughness, and hole error. The study also aims to develop a correlation between feed rate, cutting velocity, drill diameter, and filler content with the delamination factor, surface roughness, taper error, and circularity error in a GFRP material. The observed results show that clamshells filled GFRP shows lower delamination, surface roughness, circularity error, and taper error compared to cenosphere filled GFRP composites under the same process parameters. It indicates the positive impact of the fillers in the drilling of GFRP, where the main objective is to reduce drilling-induced defects.