Hole Quality Assessment in Drilling of Glass Microballoon/Epoxy Syntactic Foams

Syntactic foams reinforced with glass microballoons are used as alternatives for conventional materials in structural application of aircrafts and automobiles due to their unique properties such as light weight, high compressive strength, and low moisture absorption. Drilling is the most commonly used process of making holes for assembling structural components. In the present investigation, grey relation analysis (GRA) is used to optimize cutting speed, feed, drill diameter, and filler content to minimize cylindricity, circularity error, and damage factor. Experiments based on full factorial design are conducted using a vertical computer numerical control machine and tungsten carbide twist drills. GRA reveals that a combination of lower cutting speed, filler content, and drill diameter produces a good quality hole at optimum intermediate feed in drilling syntactic foams composites. GRA also shows that the drill diameter has a significant effect on the hole quality. Furthermore, damage on the hole exit side is analyzed using a scanning electron microscope.