Investigation of Machining Accuracy in Sisal Fibre-Reinforced Composites: Effects of Process Parameters in Abrasive Water Jet Machining for Sustainable Manufacturing

In this research paper, the effect of abrasive water jet (AWJ) machining process parameters such as jet operating pressure, feed rate, abrasive concentration and standoff distance (SOD) on the surface roughness produced during machining of graphite mixed glass fibre reinforced polymer (GFRP) composite is investigated. Experiments were conducted using Taguchi's L27 orthogonal array design and the process parameters were optimised to obtain high surface finish. Experimental data were analysed using analysis of variance (ANOVA) which shows that the surface roughness decreased by 15.90% and increased by 9.22% for the increase in operating pressure and SOD respectively. Also, regression model is developed to predict the surface roughness and found that the predicted values are in close agreement with the experimental values (error 6.57%).

In this research paper, the effect of abrasive water jet (AWJ) machining process parameters such as jet operating pressure, feed rate, abrasive concentration and standoff distance (SOD) on the surface roughness produced during machining of graphite mixed glass fibre reinforced polymer (GFRP) composite is investigated. Experiments were conducted using Taguchi's L27 orthogonal array design and the process parameters were optimised to obtain high surface finish. Experimental data were analysed using analysis of variance (ANOVA) which shows that the surface roughness decreased by 15.90% and increased by 9.22% for the increase in operating pressure and SOD respectively. Also, regression model is developed to predict the surface roughness and found that the predicted values are in close agreement with the experimental values (error 6.57%).

The selection of parameters for abrasive water suspension jet (AWSJ) machining of GFRP composites is a major aspect to be considered for optimizing the process. Generally, machining of plastics, polymer matrix composites are accomplished by the AWSJ machining carried out in the presence of atmospheric air; however, the existence of air around the AWSJ may lead to expansion of jet which results in increase in the kerf width and surface roughness; thus to overcome this drawback, an effort has been made in the current work to compare the effect of different process parameters on kerf width and surface roughness while using AWSJ techniques for machining glass fibre-reinforced plastic composite submerged in water. The exploratory outcomes have herewith validated the fact that the surface roughness and kerf width diminishes in under water machining when contrasted with that of free air machining; this is majorly attributed to the fact that the jet diameter reduces in under water AWSJ machining, thereby reducing the kerf width and surface roughness for optimized values of the parameters of speed, feed and standoff distance. Further, the experimental trials have clearly shown that the AWSJ machining used with an optimized set of parameters yields better machining capabilities as compared to abrasive water jet machining.

Abrasive water jet machining is a non-conventional machining process based on sending abrasive material accelerated with high pressure water on to the planes of focused materials with the purpose to cut various engineering materials. Abrasive water jet machining process has various machining process parameters, which in turn will affect the performance parameters. The combination of all the process parameters results in desired output. Hence it is important to find the optimal combination of process parameters. Several optimization techniques have been used to optimize these parameters. Cohort intelligence (CI) is a socio-inspired algorithm based on artificial intelligence conceptions. Further researchers have developed seven variations of cohort intelligence algorithm. The present work investigates the application of four variations of cohort intelligence for the AWJM process parameter optimization. Variations of CI have been applied for the first time in manufacturing optimization. The considered problem involves optimization of commonly used responses Surface Roughness (Ra) and kerf and results are compared with Firefly Algorithm (FA). The performance of cohort intelligence algorithm is found to be much better than firefly algorithm for four variations.

Metal matrix composites are difficult to machine in traditional machining methods. Abrasive water jet machining is a state-of-the art technology which enables machining of practically all engineering materials. This article deals with the investigation on optimization of process parameters of abrasive water jet machining of hybrid aluminium 7075 metal matrix composites with 5%, 10% and 15% of TiC and B4C (equal amount of each) reinforcement. The kerf characteristics such as kerf top width, kerf angle and surface roughness were studied against the abrasive water jet machining process parameters, namely, water jet pressure, jet traverse speed and standoff distance. Contribution of these parameters on responses was determined by analysis of variance. Regression models were obtained for kerf characteristics. Contribution of traverse speed was found to be more than other parameters in affecting top kerf width. Water jet pressure influenced more in affecting kerf angle and surface finish. The microstructures of machined surfaces were also analysed by scanning electron microscopy. The scanning electron microscopy investigations exposed the plastic deformation cutting of hybrid 7075 aluminium metal matrix composite. X-ray diffraction analysis results proved the non-entrapment of abrasive particle on the machined surface.

Selection of optimal process parameters by Taguchi method for Drilling GFRP composites using Abrasive Water jet machining Technique

Abrasive water jet cutting is one of the most recently developed non-traditional manufacturing technologies. In this machining, the abrasives are mixed with suspended liquid to form semi liquid mixture. The general nature of flow through the machining, results in fleeting wear of the nozzle which decrease the cutting performance. The inlet pressure of the abrasive water suspension has main effect on the major destruction characteristics of the inner surface of the nozzle. The aim of the project is to analyze the effect of inlet pressure on wall shear and exit kinetic energy. The analysis could be carried out by changing the taper angle of the nozzle, so as to obtain optimized process parameters for minimum nozzle wear. The two phase flow analysis would be carried by using computational fluid dynamics tool CFX. It is also used to analyze the flow characteristics of abrasive water jet machining on the inner surface of the nozzle. The availability of optimized process parameters of abrasive water jet machining (AWJM) is limited to water and experimental test can be cost prohibitive. In this case, Computational fluid dynamics analysis would provide better results.

Influence of abrasive water jet machining process parameters on accuracy of hole dimensions in glass fiber reinforced polymer composites

The present article focuses on mechanism of delamination and kerf geometry in abrasive water jet machining of carbon epoxy composite. In the present study, four process parameters of abrasive water jet machining namely hydraulic pressure, traverse rate, stand-off distance, and abrasive mass flow rate are considered. The experiments are performed on the basis of response surface methodology as a statistical design of experiment approach. Delamination in machined samples is observed by using scanning electron microscope. Analysis of variance is performed in order to investigate the influence of process parameters on delamination, kerf taper ratio, and kerf top width. It is found that delamination decreases with increase in pressure and abrasive mass flow rate and decrease in stand-off distance and traverse rate. Kerf taper ratio decreases with increase in pressure and decrease in traverse rate and stand-off distance. Kerf top width decreases with decrease in stand-off distance and increase in traverse rate. Based on analysis, mathematical models are developed to predict the maximum delamination length, kerf taper ratio, and kerf top width. Further, a multi-response optimization is performed on the basis of desirability function to minimize delamination, kerf taper ratio, and kerf top width.

This study investigates the effect of abrasive water jet (AWJ) machining parameters on the kerf width geometric characteristics of Ti-alloy workpieces. Taguchi's design of experiments were used to evaluate the influence of standoff distance, abrasive mass flow rate, and traverse speed on kerf width The results indicate that nozzle traverse speed is the most significant factor affecting the top kerf width. This suggests that controlling the traverse speed is crucial for achieving desired kerf width and maintaining machining precision. Water pressure emerges as the second most significant factor influencing the kerf taper angle and the surface roughness. This implies that water pressure plays a dual role in shaping the kerf geometry and affecting surface quality. The abrasive flow rate is found to have the least significant impact on the kerf characteristics. This suggests that the erosive power of the AWJ jet is primarily governed by the water pressure and the traverse speed, while the abrasive mass flow rate plays a secondary role. Overall, the study highlights the importance of understanding the interplay between AWJ process parameters and their influence on kerf geometry and surface quality. Optimizing these parameters can lead to improved machining precision and enhanced product quality in Ti-alloy manufacturing. Keywords: Abrasive Water jet Machining, Ti-alloys, Kerf width, Taguchi Design, Standoff distance, Abrasive mass flow rate, traverse speed

Investigation on effect of process parameters in abrasive Jet Machining process using full factorial design

An investigation on machining characteristics in abrasive water jet machining of hybrid laminated composites with SiC nano particles

Investigation on glass/epoxy composite surfaces machined by abrasive water jet machining

Investigation of gelatin enabled abrasive water slurry jet machining (AWSJM)

The growing demand of efficient materials in automobile and aircraft industries originates the development of metal matrix composites (MMCs) with excellent properties such as higher strength, hardness and stiffness, better corrosive and wear resistance and thermal properties. However, these materials are not produced at a larger scale because of its poor machining performance due to the presence of hard abrasive particle which leads to high tool wear and meager machining outputs. This paper deals with the abrasive waterjet turning of the newly developed hybrid MMC of A359/B4C/Al2O3 produced by electromagnetic stir casting method. The main aim of the study is to discuss the effect of process parameters of abrasive waterjet machining on outcomes such as surface roughness and metal removal rate. Response surface methodology and ANOVA analysis has been applied to discuss the significant level of process parameters and their mathematical relations. The results reveals that each output response considered in the study was significantly affected by the machining process parameters. The surface roughness is found in the range of 6.0545 µm to 8.3825 µm, and MRR varies from 434.72 mm3/min to 565.02 mm3/min.