Experimental and analytical study of drilling hybrid glass/carbon fibre reinforced epoxy composite

Abstract

Hybrid composites have become increasingly attractive in research and development activities in recent times due to the capabilities to tailor their mechanical performance or characteristics to specific needs. Current research and innovation in the field of hybrid composites include processing, development and testing of metal matrix hybrid composites as well as the synthetic and natural fibre hybrid composites. Nonetheless, a number of complications arise in the manufacturing processes, particularly in machining such as drilling, of these multiphase laminated materials. The fact is that machining of composites or hybrid composites presents a great challenge due to anisotropic nature of the material, lack of plastic deformation and abrasiveness of the fibre reinforcements. According to the previous statistic studies, unqualified holes leads to approximately 60 % part rejections during the final assembly process. Therefore, this research study pursues an experimental and analytical approaches to extend the fundamental knowledge in drilling hybrid fibre reinforced polymer (FRP) composites. Prior to the drilling tests, the evaluations of the mechanical performance of hybrid FRP composite have been attempted. Specifically, the hybrid effect of the plain woven carbon and E-glass fibres hybrid composites within an epoxy polymer matrix was experimentally evaluated. It was evident that the physical properties and mechanical strength of monolithic fibres composite were enhanced 48 % by hybridising carbon fibres into the glass FRP composites. In addition, theoretical analysis through the rule of mixture reveals that the hybrid FRP composites have exhibited a positive hybrid effect in term of tensile and flexural behaviors. Even though fabrication technology for the hybrid FRP composites has well advanced in the production of near-net shape components, the secondary machining process is vital for completing the postmanufactured of these materials. Thus, the desired setting for minimising the delamination damage and surface roughness were determined using the Taguchi methodology and statistical analyses.