Optimization of Machining Parameters for Enhanced Performance of Glass-Fibre-Reinforced Plastic (GFRP) Composites Using Design of Experiments

Abstract

A high strength-to-weight ratio, stiffness, fatigue resistance, a low coefficient of thermal expansion, and tailorable properties make glass-fibre-reinforced plastic (GFRP) a popular choice for a wide range of applications, including aircraft structures, automobile chassis, and shipbuilding. However, milling GFRP composites is challenging because of their heterogeneous nature and two-phase structure, which lead to high cutting forces and delamination. A statistical experiment was carried out using the Taguchi design of experiments to investigate the effect of machining settings on GFRP composite performance metrics such as surface delamination, surface roughness, and material removal rate. The L27 orthogonal array was used for the experiment, and it served as the foundation for the choice of material, input variables, levels, and output response variables. The experiment’s outcomes were analysed using MINITAB software® 18 Version and the Analysis of Variance (ANOVA) method. Based on the signal-to-noise (S/N) ratio, the ideal conditions were selected, and confirmation studies were carried out to ensure their applicability. In order to identify the ideal circumstances for the manufacturing and machining parameters, the data were normalised to a range from zero to one. To overcome the difficulties involved in milling GFRP composites, a thorough investigation and optimisation of the manufacturing process factors and machining settings is essential.