Sensitivity analysis of abrasive air-jet machining parameters on machinability of carbon and glass fiber reinforced hybrid composites

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Carbon and glass fiber reinforced epoxy polymer hybrid composites facilitate to tailor the mechanical properties of the composites. However, the machining of hybrid fiber reinforced polymer composite is a challenge by conventional processes due to the different types of fiber reinforcements and anisotropic nature of composites. Researchers and scientists have evaluated the machinability of plain or single fiber reinforced polymer composites through abrasive water jet machining and abrasive air jet machining. Therefore, the present investigation emphasizes on the development of symmetrical hybrid composites, evaluation of mechanical properties and machining of the hybrid composites through abrasive air jet machining (AAJM). There are three types of hybrid composites such as C2G3]S, [CG3C]S and [CG2CG]S along with plain glass ([G]10) and carbon ([C]10) fiber reinforced polymer composites fabricated by hand lay-up technique. It is observed that the [CG2CG]S type hybrid composite has the optimum tensile and flexural strength as compared to other composites. Hence, [CG2CG]S type hybrid composites along with plain glass and carbon fiber reinforced polymer composites was considered for the machinability study. The sensitivity of AAJM process parameters on material removal rate (MRR), depth of cut (DOC) and surface roughness (Ra) are investigated and optimized through response surface methodology (RSM). The optimum machining process output predicted by the RSM model for [CG2CG]S type hybrid composite is MRR = 3.26 × 10−3 g/sec, DOC = 1.48 mm and surface roughness (Ra) = 1.48 μm. The predicted model results compared with the experimental values and found a good agreement between them. The surface morphology of the drilled composite sample is investigated under scanning electron microscope. It is observed that the surface damage of the drilled surface of the composites is minimal. Thus, the abrasive air jet machining process can be employed for drilling of polymer matrix composites to overcome the conventional machining issues.