Machining GLARE fibre metal laminates: a comparative study on drilling effect between conventional and ultrasonic-assisted drilling

GLARE laminates are multi-layered metal-composite materials created from bonding sheets of metallic alloys with carbon or glass fibre layers. The application of hybrid-conventional machining processes such as ultrasonic-assisted drilling (UAD) is becoming of great interest to the aerospace industry due to its capability in reducing the cutting forces and tool wear which are directly responsible for drilling-induced delamination. There is rich literature on the conventional drilling (CD) of GLARE, but no work reported using UAD process. This study will fill this gap and investigate the UAD of GLARE laminates using an indigenously developed UAD system. The influence of spindle speed and feed rate on thrust force and surface roughness metrics (R_a and R_z) were investigated under CD and UAD regimes. The quality of the borehole and damage mechanisms in the laminate constituents was examined using scanning electron microscopy (SEM). The contribution of the drilling parameters on the measured outputs was further evaluated using the analysis of variance (ANOVA) statistical analysis. It was found that UAD resulted in a significant reduction in thrust force by up to 65% while surface roughness metrics R_a and R_z were unaffected by the type of drilling process used. SEM analysis showed irregular and fuzzier surfaces in glass fibre layers in holes machined using UAD due to the longitudinal vibration of the tool.