Effects of wax and graphene concentrations on cutting force in drilling GFRP composites: A comprehensive study using a full factorial design of experiments

Abstract

This study investigates the effects of varying concentrations of wax (0%, 1%, and 2%) and graphene (0%, 0.25%, and 2%) on cutting forces during the drilling of Glass Fiber Reinforced Polymer (GFRP) composites. A full factorial design of experiments (DOE) was employed to evaluate the interaction between these variables. Wax enhances lubrication and reduces friction, while graphene contributes to material strength and thermal conductivity, thus affecting machining performance. GFRP samples with different wax and graphene concentrations were prepared using a consistent mixing process. Cutting forces were measured during drilling, and normality tests confirmed that the data followed a normal distribution, allowing for the use of parametric statistical methods. Regression models were developed to assess the impact of different concentrations on cutting force, with t-tests evaluating the significance of the factors. The results indicated that the optimal combination for minimizing cutting forces was 1% wax and 0.25% graphene. This study highlights the importance of adjusting wax and graphene concentrations to optimize drilling performance, offering insights into the most effective combinations for reduced cutting forces. The predictive accuracy of the regression models was high, with R² values of 0.95 and 0.90, respectively.