Multiscale modelling and experimental analysis of ultrasonic-assisted drilling of GLARE fibre metal laminates

Muhammad Atif, Xibin Wang, Lijing Xie*, Khaled Giasin, Yuan Ma, Chulin Jiang, Ugur Koklu, Jos Sinke

*Corresponding author for this work

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This study aims to evaluate the effectiveness of Ultrasonic-assisted drilling (UAD) of Glass laminate aluminium reinforced epoxy (GLARE) at high cutting speeds (Spindle speeds: 3000–7500 rpm; feed rates 300–750 mm/min) by analysing the thrust force and hole quality metrics (surface roughness, hole size, and burr formations. The research also presents numerical modelling of FMLs under conventional and UAD regimes to predict thrust force using ABAQUS/SIMULIA. The thrust force and exit burrs were reduced by up to 40.83 % and 80 %, respectively. The surface roughness metrics (Ra and Rz) were slightly higher using UAD but remained within the desirable limits of surface roughness for machined aeronautical structures. The discrepancy between the simulation and experimental results was adequate and did not exceed 15 %. The current study shows that it is feasible to drill holes in GLARE using higher cutting parameters and maintain excellent hole quality, which means increased productivity and reduced costs.

Original languageEnglish
Article number107962
Number of pages20
JournalComposites Part A: Applied Science and Manufacturing
Early online date19 Dec 2023
Publication statusPublished - 1 Feb 2024


  • surface roughness
  • thrust force
  • ultrasonic assisted drilling

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