Optimization of AWJ parameters for improved material removal and hole geometry in drilling of Glass Fiber/Aluminum mesh epoxy hybrid composites

This study explores the application of abrasive waterjet drilling (AWJD) for varied patterns of GF/Al mesh hybrid composites (neat glass NG, AG: Al in the exterior surface, and GA: Al in the center). Key parameters such as jet pressure (P), standoff distance (S), and traverse speed (V) are systematically varied, influencing material removal rate (MRR), hole taper ratio ((Formula presented.)), and roundness error ((Formula presented.)). Employing a Taguchi approach with an L9 design. It was indicated that the optimal conditions for maximum MRR are (P: 150 MPa, S: 2 mm, and V: 900 mm/min). V and S are the main influential parameters on (Formula presented.) and (Formula presented.). Gray relational analysis (GRA) is employed for simultaneous optimization, enhancing drilling performance. The optimal parameters P of 150 MPa, S of 2 mm, and V of 300 mm/min are determined. Validation trials confirm the effectiveness of the determined parameters. A robust multiple regression equation is formulated, providing a predictive model that aligns closely with experimental observations. Highlights: The hybrid composites were drilled via a nontraditional process. The attributes of the hole geometry and the material removal impacts were studied. Operation parameters were optimized to improve MRR, (Formula presented.), and (Formula presented.). A multiple regression model and a confirmation test were performed and validated.