Cutting force and delamination optimization of nanoparticle-reinforced basalt/epoxy multi-scale composites in dry drilling by Taguchi design

Purpose The real-time performance requirements of montage components and assembly features of structural parts are among the most critical factors for the utilization of polymer-matrix laminates in the aerospace industry. In this context, the present study provides a comprehensive perspective on the dry drilling optimization of nanographene-added basalt fiber-reinforced epoxy composite laminates, focusing on cutting force and surface delamination damage. Design/methodology/approach The combined effects of feed rate (FR) (0.10, 0.15 and 0.20 mm/rev), tool diameter (3 and 5 mm) and nanographene ratio (0, 0.3 and 0.7 wt.%) were investigated as input parameters using a specially designed dagger tool for the first time in the literature. Additionally, Taguchi’s L18 design was employed to determine the optimal combination of input variables. Findings The results indicate that lower feed rates, smaller tool diameters and higher nanoparticle concentrations result in the lowest cutting forces. As for the delamination factor, lower feed rates, larger tool diameters and higher nanoparticle concentrations were identified as the best combination to maintain the structural integrity of the machined surfaces. Only localized minor chips were seen at the best combination. Detected outcomes can be used for future projects that aim to explore the joining strength of mechanical assembly for aircraft laminate structures. Originality/value Achieving high-performance composite assemblies in aerospace applications (particularly in wing, fuselage and interior components), with sufficient mechanical properties, requires precise optimization of drilling operations to ensure strong joints and high-quality surfaces without delamination defects. This study, specifically focusing on nanoparticle-modified basalt fiber-reinforced laminates for aerospace implementations, is the first to elucidate the combined effects of FR, tool diameter and nanoparticle ratio on thrust force and delamination factor.