Machinability characteristics study on hibiscus rosa-sinensis reinforced polymer composites using soft computing techniques

Abstract Understanding the drilling behaviour of composite materials is crucial for optimizing their manufacturing processes and enhancing their applicability across various industries. In this study, the drilling process of Hibiscus Rosa-Sinensis Polymer matrix composites is investigated due to the significance of investigating such advanced and sustainable composite materials for their potential applications. Hibiscus Rosa-Sinensis Fibers are extracted and processed from the outer bark of the hibiscus plant, are incorporated into polymer matrices in varying weight percentages (0 Wt%, 10 Wt%, 20 Wt%) to form discontinuously reinforced polymer composites. Samples with uniform dimensions of 150 × 75 × 15 mm, are used for the drilling operation using Ace Micromatic DTC-400 instrument. The project focuses on analysing the influence of key drilling input parameters such as Spindle speed, Feed rate and HRS (Hibiscus Rosa-Sinensis) Fiber weight percentage on the Thrust Force (N) and Torque (N-m) generated during drilling operations. Taguchi’s Design of Experiments with L27 orthogonal array is used to systematically optimize the input parameters to gain insights into the drilling behaviour of these composite materials. Further a second order mathematical model has been generated for Thrust Force and Torque using Response Surface Methodology (RSM). Thrust Force and Torque during drilling are measured using 9257 BA KISTLER Dynamometer coupled with DynoWare 2825 A software. The findings of this study not only contribute to a deeper understanding of the drilling process but also hold significant implications for industries reliant on composite materials. From aerospace to automotive sectors, where lightweight and durable materials are essential, to construction and renewable energy industries seeking sustainable alternatives, the application potential of hibiscus Rosa-Sinensis Fiber-reinforced composites is vast. By elucidating the intricate dynamics of drilling operations on these materials, this research paves the way for enhanced manufacturing processes and the development of advanced composite structures tailored to meet the demands of diverse industrial applications.