Optimization of CO2 laser drilling process parameters of GFRP/Al2O3/perlite composites

Abstract

Glass Fiber Reinforced Polymer (GFRP) composites have excellent mechanical characteristics and are extensively used in aerospace and marine applications. Drilling GFRP composite through conventional methods leads to delamination and taperness, causing quality loss and imprecision. CO2 laser drilling, an unconventional method to drill GFRP composites, is adopted in this study to reduce the delamination and taperness. This work aims at optimizing the process parameters of CO2 laser drilling. Hybrid S-glass/Al2O3/Perlite powder composite is used in this study. Laser drilling parameters: laser power (P), cutting speed (N), focal length (L), and hole diameter(d) were studied to reduce the hole delamination and hole taperness. These results were achieved through mathematical modelling and optimization using Response Surface Methodology (RSM) and Multi-Objective Genetic Algorithm (MOGA). The optimum process parameters were found by minimizing the objective function upon considering the drilled holes economic features, deposition efficiency, geometric features, and hole diameter at larger and smaller sides. The most critical output factors, delamination and taper responses, had a deviation from the objective by less than 3%. The optimum process parameters laser power, cutting speed, and focal length is found to be 80.795 W, 7.9089 mm/sec, and − 1.9641 m respectively. From the experimental confirmation study, the optimum process parameters effectively reduced the hole delamination and taperness.