Selection of optimal process parameters by Taguchi method for Drilling GFRP composites using Abrasive Water jet machining Technique

Abstract

Abrasive Water Jet Machining (AWJM) is an unconventional machining process which is employed for production of bolt holes on brittle and hard materials such as composite materials, alloys, ceramics and intricate electronics components, for assembly of structural frames. The strength of the assembled joint depends on the quality holes made by the abrasive water jet technique, so it is important to understand the applications of AWJM process on GFRP composites by the industry. The aim of present experimental work is to optimize the machining process parameters of abrasive water jet machining on Glass fiber reinforced plastic composite for making holes. In this work, experiments are carried out as per the taguchi experimental design and selected an L9 orthogonal array to study the influence of various process parameters on Material removal rate and surface roughness and hole quality. The selected machining process parameters are abrasive flow rate, pressure, standoff distance and fiber orientation. From the experimental results maximum material removal rate observed at a pressure of 225Mpa, mass flow rate of 400g/min ,standoff distance of 1.5mm and fiber orientation of 45o. Also observed optimum hole accuracy at pressure of 175Mpa, mass flow rate of 300g/min, standoff distance of 1.5mm and fiber orientation of 90o. From the experimental results it is found that material removal rate, hole accuracy and surface roughness are mainly influenced by the, standoff distance, pressure and abrasive flow rate . Taguchi technique is used for optimizing the effect of predicted variables on response variable. The experimental results are analyzed by using analysis of means.