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 (), and roundness error (). 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 and . 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, , and . A multiple regression model and a confirmation test were performed and validated.