Machinability and surface integrity of glass fiber reinforced plastic composite: A review
Artur Camposo Pereira, Sérgio Neves Monteiro, Leonardo Rosa Ribeiro da Silva, Rüstem Binali, Mustafa Kuntoğlu, Álisson Rocha Machado, Danil Yurievich Pimenov
Abstract
Glass fiber reinforced plastic (GFRP) composites, initially developed for home insulation, are now essential in aerospace, automotive, marine, and construction industries due to their lightweight, corrosion resistance , and high mechanical strength . However, their anisotropic and heterogeneous nature, coupled with the abrasive behavior of glass fibers, poses significant machining challenges, including rapid tool wear , surface defects , delamination , and subsurface damage. This review systematically examines recent advancements and strategies to address these challenges across machining methods such as turning, milling, drilling, grinding , and tapping . It highlights the influence of cutting regimes, tool geometries, and advanced coatings on machinability and surface integrity. The review also evaluates the impact of cutting environments, including cryogenic cooling , minimum quantity lubrication , and hybrid machining, on cutting forces, tool wear, chip morphology, and surface quality. A key contribution is the exploration of emerging techniques like vibration-assisted and thermally-assisted machining, alongside computational tools such as finite element modeling , artificial intelligence, and artificial neural networks . These tools optimize machining conditions, predict outcomes, and reduce experimental costs. Promising strategies, including advanced coatings (e.g., PCD , TiN, CBN) and simulation-driven approaches, are identified to enhance machinability. By addressing the complex interplay between machining parameters, material properties, and surface quality, this article offers a concise framework for improving the precision, efficiency, and cost-effectiveness of machining GFRPs , paving the way for optimized processes in next-generation composite materials.