This study aimed to develop, characterize, and optimize abrasive waterjet (AWJ) machining of sustainable basalt fiber-reinforced polymer composites for construction and industrial applications. Dynamic mechanical analysis, thermogravimetric analysis, and X-ray diffraction revealed enhanced thermal stability, increased decomposition temperatures, and improved crystallinity, correlating with improved tensile strength of developed composites. To address drilling-induced damage that can compromise long-term quality and applicability, AWJ drilling parameters were optimized to minimize damage while enhancing material removal rates. A novel quantification method for entry total surface damage (ETD) was implemented to assess machining defects. Results showed that standoff distance significantly influences ETD and exit delamination, while higher water pressure reduces entry damage. Abrasive flow rate primarily affected the material removal rate. FE-SEM analysis revealed microstructural changes in drilled surfaces, including damage zones and matrix fractures specific to AWJ processing. Multi-objective optimization using Genetic Algorithm is performed to enable flexible parameter selection and informed decision making, balancing machining efficiency and minimal damage.
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