1. Introduction
Glass-fiber-reinforced polymer (GFRP) matrix composite materials are widely used in many sectors, such as the automotive, marine and aviation industries. Especially in the aviation sector, its features are also developing accordingly, while the usage rates are increasing day by day. Their superior properties, such as high mechanical properties and light weight, resistance to chemical and environmental conditions, make these materials more and more attractive.
Lighter and stronger materials can be manufactured with nanoparticle reinforcement. In this context, nanocomposites are accepted as one of the best materials that can meet all the requirements. The superior mechanical properties of (GFRP)MWCNTs make them the preferred filler for reinforcement in composite material [
1]. In particular, nanocomposites, namely multi-walled carbon nanotubes (MWCNTs)-added GFRPs, exhibit favorable material properties at low weight percentages due to the corrosive nature of their reinforced components.
They are usually produced close to the net shape when manufacturing composite materials. However, the final stage for using these products usually requires machining or drilling. The life of the puncture joint in composite materials is directly affected by the quality of the drilled holes [
2,
3,
4]. During the drilling of fiber-reinforced composites, different types of damage can occur in the hole, such as microcracks, fiber shrinkage, and matrix burning, as well as delamination. Delamination errors are a major cause of part rejections in assemblies, especially in the aerospace industry, and it is one of the most frequent types of failures in fiber-reinforced composites. A drill bit performance can be determined from a variety of variables such as the thrust or torque required, good hole tolerances and surface finish, and drill life [
5,
6,
7].
Although many parameters are considered in drilling fiber-reinforced composites, parameters such as drill type, drill diameter, feed rate, and spindle speed are generally used in studies [
8]. The drilling process occurring in a confined space is challenging to control, which adversely affects outputs such as delamination, roughness, torque, and thrust force [
9].
Rajamurugan et al. [
10] modeled the empirical relationship between delamination and input parameters in drilling GFRP composites. They mentioned that the increase in feed rate increases the separation of parts between the layers and the cutting speed reduces delamination. Similarly, in drilling composite materials, the use of an appropriate drill bit angle plays a crucial role in reducing the main defects such as delamination and surface roughness by minimizing the thrust force [
11]. Ekici et al. [
12] investigated the effects of input parameters on surface roughness, delamination factor, and thrust force when perforating a commercial laminate, CARALL-type composite. The authors used the PCA weighting-based Grey Relational Analysis (GRA) method for the multi-objective optimization of the outputs.
In a study on the machinability of CET/epoxy materials, the effect of machining parameters in drilling on thrust force and delamination was investigated. It was observed that the delamination size increased with the increase in the revolution and feed rate. In addition, it was determined that the thrust force and thus the delamination size increased at high feed rates. It was stated that the increase in the feed rate also affects the surface roughness negatively [
13]. Many researchers observed in their studies that the level of delamination is related to the thrust force and that delamination can be neglected if the thrust force is below the critical value [
14].
Thanks to the lubricating properties of MWCNTs in different proportions added to the composite, it has been observed that these reduce delamination by improving some situations such as fiber bending and shearing, and plastic deformation that occur during drilling. Therefore, to acquire a good result, it is necessary to better understand both the material properties and the machining process [
15,
16,
17].
In production, the selection of the most suitable process parameters is of great importance in order to reduce the cost and improve the quality. The selection of appropriate process parameters in an experimental process has an important contribution to the determination of the optimal or best experimental conditions [
18,
19]. One of the most important parameters that affect the quality of drilled hole in the processing of composites is the selection of the drill tool material, which is a direct function of the torque and thrust force generated during drilling. In the drilling of GFRP composites, commonly used drill tools include coated and uncoated high-speed steel (HSS) drills, coated and uncoated carbide tools using different methods (i.e., PVD, CVD), and polycrystalline diamond (PCD) tools [
19,
20,
21,
22]. In the investigated literature, the studies have been conducted using various drill bit sizes. Valarmathi et al. [
23] suggested in their study that an increase in drill diameter increases delamination. According to the experimental results, it is evident that in order to minimize delamination, suitable cutting conditions involve high spindle speed, low feed rate, and smaller drill diameter.
Multi-criteria decision-making (MCDM) methods are the methods that choose the most suitable one among the available alternatives under certain constraints in decision problems where more than one objective is optimized. Until now, many different MCDM techniques have been used for parameter optimization, especially in the manufacturing industry [
24,
25,
26,
27]. Kalyanakuma et al. [
28] optimized the drilling parameters of 316 types of stainless steel by using the VIKOR (Serbian; VlseKriterijumska Optimizacija I Kompromisno Resenje) method. They used a Taguchi L27 orthogonal experimental design in the study and selected the input parameters with the responses. The Taguchi method is a method used for single-response optimization. Determining the significance of the impact of different processing parameters on the outputs is crucial. Taguchi (S/N)-based MCDM methods are used to transform multiple responses into a single response, and they have been utilized in many studies in the literature [
29,
30,
31].
The most important criterion affecting the ranking obtained from MCDM methods is the selection of the weighting values of the responses. In the application of multi-objective decision-making techniques, although it is mostly weights of similar importance that are assigned to determine the response weights in the process of converting multiple responses to single response values, various techniques have been developed to assign importance weights to the responses. The selection of weights, which is very important in determining the optimum alternative for MCDM problems, also depends on the selection of the weighting method [
29]. In the literature, criteria weighting methods are used as subjective, objective or a combination of these two methods. Among these techniques, many methods, such as the Entropy method, Critic method, AHP method, Fuzzy AHP method, Least Squares Method, SWARA method, have been used in previous studies [
32].
Numerous authors have developed new methods to find the optimal ranking using more than one MCDM method in their studies. In this way, the results produced using different MCDM methods can be observed. For this reason, the optimization of optimum drilling conditions was investigated by applying three different MCDM methods in the study [
33].
Researchers use the WASPAS (Weighted Aggregated Sum Product Assessment) technique to select the best alternative from the set of available feasible alternatives/solutions in different engineering domains [
34]. It is stated that this method has the ability to accurately rank alternatives in all selection problems and provides better or equivalent results than other methods [
35].
According to the results of the reviewed literature, it is clear that the MCDM methods have achieved very successful results in the optimization of the multi-response machining parameters, thus improving the overall machining performance. However, there do not exist studies in which MCDM methods are applied using similar parameters in the processing of GFRPs, as they are in this study. In the literature, no study was reported in which all three methods (GRA, WASPAS and VIKOR) were compared.
This study intends to fill this gap by focusing on statistical, modeling and optimization studies of performance parameters. In this study, a multi-objective optimization study was carried out to find the optimum cutting conditions that minimize all outputs at the same time, at three levels of four input parameters. To carry this out, three different MCDM methods (GRA, WASPAS and VIKOR) based on the Taguchi (S/N) method were used. Among the weighting methods used in the MCDM problems, the Fuzzy AHP method based on expert opinion was used. Finally, the rankings of the alternatives obtained according to each MCDM method were analyzed and compared with each other. The results obtained show that the optimization method based on Taguchi S/N MCDM method has excellent potential in solving multi-objective optimization problems used in engineering.
2. Materials and Methods
2.1. Workpiece and Fabrication of Specimens
In the present work, the effects of drilling parameters on the output parameters in drilling GFRP composite materials have been investigated. Drill type, spindle speed, feed rate, and nano content amount were chosen as control parameters, and four main response factors (i.e., surface roughness, delamination, torque, and thrust force) have been considered. The specimen material used in the experiments was a GFRP (glass-fiber-reinforced polymer) made of pre–preg glass fiber epoxy resin, manufactured by İnovatif Material Technologies Inc. in Izmir, Turkey. The GFRP composite was produced by weight with 0.5% and 1% additives, without any additives. Detailed information about the production of the composite can be accessed from the study conducted by Fedai and colleagues [
36].
2.2. Drilling Tool, Drilling Process and Measurements of Output Parameters
The drilling experiments of the composites were performed using the Johnford VMC 850 model three axes CNC Fanuc system vertical machine center equipped with a maximum spindle speed of 8000 rpm, cutting feed 12.000 mm/min, and a 7.5 kW drive motor. The experiments were conducted under dry-cutting conditions. The steps of the experimental process are shown in
Figure 1.
Three different cutting tools were used in the experiments, which were Ø8 mm uncoated HSS, carbide, and TiAlN-coated tools. The selection of the cutting tools was based on the professional experience of the tool manufacturer and recommendations from the literature. In order to ensure consistent effects on the outputs, cutting tools with the same diameter and tooltip angle were chosen from widely used tool types in practice. HSS tools were preferred due to their cost-effectiveness, while carbide and coated tools were preferred for their longer tool life. In each experiment, a new cutting tool was used to prevent the influence of tool wear on the experiments. The characteristics of the used cutting tools are provided in
Table 1.
The thrust force and torque are measured during work with the Kistler 9257B dynamometer, which is connected to the machine table of the vertical machining center. The data obtained from the dynamometer were recorded on the computer using the Kistler Type 5070 amplifier A/D converter and DynoWare (version 2.4.1.3) software. Each experiment was repeated three times, and the arithmetic average of the obtained data was taken. During data analysis, the unstable regions at the entrance and exit of the hole were neglected to avoid measurement errors.
Delamination is the most important type of damage that occurs during the drilling of laminated composites. It is frequently seen in the hole inlets and outlets on the workpiece during the drilling of composites. The maximum damaged diameter of the hole is called Dmax. The delamination factor is the ratio of Dmax to D.
In the drilling processes of composite materials, surface damage is a crucial parameter to assess the quality of the workpiece machining [
37].
After the drilling processes of the composite, offline measurement procedures were conducted for delamination and surface roughness. The delamination factor was measured using a Euromex Holland Type PB 4161 microscope.
Figure 2 shows the images obtained from the microscope, which were edited and transferred to the AutoCAD environment. The maximum diameter (Dmax) in the damaged area was measured, and the damage factor was determined by proportioning it to the normal diameter (D).
The surface roughness (Ra) value of workpieces was measured using a MITUTOYO SJ-410 transportable surface roughness tester with a cut-off interval of 4.8 mm and speed of 0.5 mm/s. Surface roughness measurements were carried out three times on the surfaces of the workpieces, and their average roughness parameters were determined. During the measurements, in order to minimize the influence of the damaged surfaces at the entrance and exit of the hole, the measurements were taken from the middle sections of the hole.
Figure 3a shows the delamination measurement of drilled composites, and
Figure 3b the hole surface roughness measurement. Hole surface roughness was averaged by measuring from four points inside the hole.
2.3. Experimental Design
Experimental design (DOE) is a method used to determine the relationship between inputs that affect a process and the output of that process. It helps to find the necessary information to manage process inputs in order to optimize the output. Traditional experimental design methods are very complex and challenging to use. Moreover, as the number of process parameters increases, these methods require a large number of experiments to be conducted. The Taguchi method is an experimental design technique developed by Taguchi to minimize variability in both product and process by selecting the most suitable combination of levels of controllable factors against uncontrollable factors that create variability in the product and process. The Taguchi method requires a carefully planned process when determining the experimental design and factor selection. The following are the steps to be used in factor selection to apply the Taguchi technique: Problem Definition, Determination of Independent Variables, Determination of Levels, Selection of Experimental Design, Implementation of Experiments, Data Analysis, Determination of the Best Combination, Interpretation and Implementation of Results. In a general sense, for quality improvement and optimization, the selected independent variables for a defined problem, which is measuring the response of different types of drills in drilling various ratios of nanocomposites, are the tool type, % MWCNT, cutting speed, and feed rate. Three different levels were chosen for each control parameter to examine changes in the response. Based on the literature and considering the limitations of the workpiece, tool type, and machine, three different levels were selected, as shown in
Table 2.
The experimental design was conducted according to a Taguchi method-based L27 array, and the use of the Taguchi orthogonal array significantly reduced the number of experiments. While a full factorial design would require 34 = 81 experiments, this number was reduced to 27. After the implementation of experiments, the data were analyzed using Taguchi metrics. Finally, based on the analysis results, the factor combination and levels that provided the best results were determined. This allows for the identification of factors and levels that yield the best performance for a specific problem. The Taguchi method provides a systematic approach, and the steps of factor selection and experimental design are crucial for the effective implementation of the Taguchi technique.
In the study, the Taguchi (S/N) technique was employed to investigate the effects of process variables on drilling performance. In the evaluation of the MCDM results, signal-to-noise (S/N) ratios, which are based on the ratio of mean to standard deviation, were used to determine the optimum parameters. The goal here is to maximize the S/N ratio. Therefore, the level with the highest calculated average S/N ratio for each parameter was used to determine the best result in the evaluations.
In the determination of the optimum parameters, the signal-to-noise S/N ratios, which are the ratio of the mean to the standard deviation, were taken as basis. The aim here is to maximize the S/N ratio. Therefore, the level with the largest S/N ratio among the average S/N ratios calculated for each parameter is used to determine the best result in the evaluations.
In this study, the Taguchi technique was used to investigate the effects of process variables on drilling performance.
2.4. Method
The values obtained from the multi-response experiments need to be carefully investigated. The response variables should not be analyzed individually and independently of the others, as the relationships among the responses will cause univariate results to be meaningless. In this case, it is pointless to obtain individual best experimental conditions if multiple responses are needed to be simultaneously optimized. Where design variables depend on uncertain factors and conflicting goals, the goal is to define a single solution that encompasses all responses. In the solution produced for this purpose, the responses to the design points are optimized and the variances are minimized. For this purpose, MCDM methods and the Taguchi method are applied in an integrated manner in the literature [
38]. The consistency of the results of some MCDM methods is still questionable. Depending on the conditions or robustness, using two or more different multi-criteria optimization methods will yield more consistent results than using a single method [
39]. In the study, different MCDM methods were used to optimize the control parameters. In this context, GRA, WASPAS and VIKOR methods were used. Fuzzy AHP method was used for criterion weighting required by all three methods. The parameters were reoptimized by applying the Taguchi S/N optimization method to the values obtained by using all three MCDM methods. In the final stage, the results of both methods were compared. The flowchart of the proposed approach is given in
Figure 4.
2.5. Determination of Criteria Weights Using Fuzzy AHP Method
The Fuzzy AHP method developed by Saaty is an improved version of the Analytical Hierarchy Process method [
40]. The AHP method is applied to the solution of the decision-making problem in fuzzy environmental conditions [
41]. Firstly, the criteria and alternatives are determined and then, the fuzzy comparison matrix is built by using the triangular fuzzy numbers After that, the fuzzy weight vector is developed and fuzzy weight vector is established [
42].
Table 3 shows the fuzzy comparison matrix for the decision-making problem in this study.
In
Table 4, the geometric means for alternatives were calculated after developing the fuzzy comparison matrix. After that, the fuzzy weights for each experiment were calculated and averaged. Then, the normalization process was performed.
Table 3 gives the geometric mean, fuzzy weights, and normalized weights.
The most important damages based on the experts’ opinion are caused by delamination during the use of GFRP composites, followed by surface roughness, force and applied torque. Delamination, surface roughness, force and torque were obtained in order of importance after the weighting procedure. These ratios are given in
Table 4, and the calculated percentages of the weights for each criterion (i.e., Dm, Ra, F and T) are as follows: 45.4%, 32%, 15.4%, 7.2%, respectively.
2.6. Fuzzy AHP-GRA Modeling
GRA is a grading, classification and decision-making technique based on the Grey Relational Grade, developed using the Grey System Theory. The GRA is a solution method that can be applied to decision problems where there are complex relations between factors. The main purpose of this method is to establish an index where alternatives can be compared with each other. The basic idea here is to determine the degree of relationship between each criterion and the reference series. The grey relational analysis method is also used in solving problems involving complex relations, as well as combined models with other MCDM methods. This study was implemented using the following steps in GRA.
Step 1: Development of the decision matrix.
The decision matrix is a matrix that must be developed by the decision maker. This matrix should be a matrix of mxn size. While the decision maker shows the alternatives in the rows, the factors are included in the columns. This matrix can be represented as in Equation (1):
Step 2: Normalization. Since there are great differences between the mathematical values of the data obtained as a result of the experiments, the data should be normalized between 0 and 1. There are many normalization methods in practice. They are classified as vector, linear and non-monotonic normalization to suit real application situations under different conditions. For GRA analysis, the following linear normalization method (see Equations (2) and (3)) is used in most studies [
43].
Since Ra, D, F and T are cost-oriented according to their quality characteristics, our objective function is to minimize these values. For this reason, the normalization process was applied according to Equation (2) for GRA.
Step 3: Calculation of grey relational coefficient (GRC). Let k denote the kth row in the series of n length. The GRC in the kth row is calculated using Equation (4).
where
is the difference in the absolute values of
and
.
is the distinguishing coefficient
(
0.5 is used in most applications).
Step 4: Grey relational grade.
When the obtained grey correlation coefficients are multiplied by the weight of the criterion and added up for each alternative, the grey correlation degree (GRG) is obtained for each alternative The GRG is represented by Equation (5).
where
(GRG) is a fuzzy-AHP weighted (w
j) value.
If the weights of each criterion are known, the grey correlation coefficient can be calculated by multiplying the grey correlation coefficient of the criterion and the criterion weight. The weights used in the study were determined according to the Fuzzy AHP method.
2.7. Fuzzy AHP-WASPAS Modeling
The WASPAS method developed by Zavadskasvd consists of a combination of Weighted Sum Model (WSM) and Weighted Product Model (WPM) methods with a coefficient indicated by λ [
44]. The steps of the WASPAS method are as follows:
Step 1: Development of the Decision Matrix.
The decision matrix showing the values of the alternatives on the basis of the determined criteria is established as shown in Equation (1).
Step 2: Development of the normalized decision matrix.
Linear normalization process is applied to the decision matrix values according to the criteria type. Since all our criteria are cost-oriented, the normalization process was performed according to Equation (7).
For benefit attributes, it is as follows:
For cost attributes, it is as follows:
Step 3: Calculating weighted sum and weighted product values.
Using the Weighted Sum and Weighted Product methods, the total relative importance of the alternative is calculated separately. The Weighted Sum is calculated by adding the criteria values multiplied by the weights. The value of each alternative is multiplied as much as the number of the relevant criterion weight, and then all these values are multiplied to calculate the Weighted Product. Q
i(1) and Q
i(2) represent the total relative importance of the ith alternative according to Weighted Sum and Weighted Product, and are calculated by using Equations (8) and (9), respectively.
Step 4: Calculating total relative importance.
The total relative importance of the alternatives calculated according to the AS and AP methods can be generalized as shown in Equation (10).
The λ used in Equation (10) takes values between 0 and 1 and is taken as 0.5 in the literature.
2.8. Fuzzy AHP-VIKOR Modeling
Opricovic and Tzeng developed this technique to solve MCDM problems involving conflicting and incomparable criteria [
45]. The method ranks the alternatives and chooses the best from these alternatives. VIKOR is a conciliatory decision-making solution technique that takes into account not only the maximum group benefit but also minimum individual regret in the search for near-ideal solutions [
27].
The VIKOR method starts by establishing the performance matrix (i.e., decision matrix). In the matrix, all alternatives (i.e., experiments) are evaluated in terms of each criterion (i.e., output parameters). The performance matrix is normalized to eliminate the unit differences of the criteria. To reflect the superiority or priority of the criteria, the normalized matrix is weighted with the previously calculated Fuzzy AHP method. Opricovic and Tzeng built a ranking that takes into account the maximum group utility and minimum regret [
45].
Step 1: Development of the decision matrix (see Equation (1)).
Step 2: Determining the best (xi*) and worst (xi−) performance value of all criteria.
Process parameters are classified as benefit-oriented (maximizing) and cost-oriented (minimizing). In this case, all outputs (Ra, Dm T and F) are chosen as cost-oriented (minimized). The smallest value (Best Value, xi*) and the largest value (worst value, xi−) for our outputs are selected.
Step 3: Determining S
i by calculating normalized and weighted normalized value of variables.
Step 4: Calculating the utility measure and the regret measure.
where
is the sum of the weighted normalized value.
where
,
∈ [0, 1], and 0 denotes the best and 1 denotes the worst situations.
Step 5: Calculating the VIKOR index.
The VIKOR index can be calculated as follows:
where v ∈ [0, 1] is a weighting factor.
Step 6: Condition to check alternatives.
As a result of checking the alternatives determined in the VIKOR method, the Qi value giving the value of v = 0.8 was accepted as the best alternative.
4. Conclusions
Today, nanocomposites are processed in different industries and have found widespread applications. In this study, the multi-walled carbon nanotube (MWCNTs)-reinforced composites are drilled by using different types of drills under dry drilling conditions. A three-level Taguchi L27 orthogonal experimental study is conducted to investigate the effects of different drilling parameters (i.e., MWCNT ratio, drill type, feed and cutting speed) on a number of output parameters (i.e., delamination factor in hole damage, surface roughness, thrust force and torque). A number of MCDM methods have been used in the literature to determine the optimal combination of drilling parameters. The GRA, WASPAS and VIKOR methods are used in this study. In this study, the fuzzy AHP method is used to weight the criteria in order to prevent subjectivity in the decision-making process. The findings from the study are given below:
The fuzzy AHP method is used to determine the criterion weights. The weighted percentages of Dm, Ra, F and T values were determined as 45.4%-32%-15.4%-7.2%, respectively.
Experiments are planned according to the Taguchi L 27 orthogonal sequence and multi-criteria optimization is performed by using three MCDM methods (i.e., GRA, WASPAS and VIKOR).
The correlation coefficient value between the rankings obtained from each MCDM method is over 90%. This result shows that the methods are compatible with each other and eliminates the possibility of obtaining any skewed results.
According to all MCDM methods, the best multi-response quality characteristic performance is achieved in the 18th test condition (i.e., A2B3C3D2- Ra = 4.86 µm, Dm = 1.13, T = 55.57 N and F = 48.00 N), while the worst performance is obtained in the 21st test condition (i.e., A2B3C3D2- Ra = 7.287 µm, Dm = 1.312, T = 23.63 N and F = 101.46 N).
According to the optimization conducted via Taguchi S/N FAHP–GRA and WASPAS, the optimum parameters are obtained under A2B3C1D1 experimental conditions (Ra = 4.86 µm, Dm = 1.10, T = 17.47 N and F = 48.33 N), and according to the optimization carried out via Taguchi S/N FAHP–VIKOR, under A2B3C2D2 experimental conditions (Ra = 5.02 µm, Dm = 1.09, T = 37.19 N and F = 45.01 N).
The comparison of MCDM and the weighted Taguchi S/N MCDM methods shows an improvement of 10.04% with Taguchi S/N FAHP–GRA and WASPAS, and 8.19% with Taguchi S/N FAHP–VIKOR.
Spearman correlation coefficients are calculated by successfully comparing the GRA, WASPAS and VIKOR methods with each other. The correlation coefficients of GRA-WASPAS, GRA-VIKOR and WASPAS-VIKOR are calculated as 0.962, 0.919 and 0.907, respectively.
In the conducted study, the single optimization of the experimental outputs was not discussed due to the constraint of the field. This study primarily focused on multi-objective optimization, criteria weighting, and the comparison of different MCDM methods. This study demonstrates that, in addition to the methods used in multi-objective optimization, the weighting of the outputs also has a significant impact on the optimization process. In the study, it is understood that companies have various demands in reaching their own goals and in applying expert opinions based on the fuzzy AHP method. While energy consumption is important for some companies, others prioritize production time. In future research, a study can be conducted in which the results are discussed by optimizing the outputs with a single MCDM method using several different weighting methods (i.e., AHP, Swara, Entropy, or Critic). Additionally, studies can be carried out by using different outputs, especially both minimization and maximization such as tool life.