Multi-performance optimization of abrasive water jet machining of carbon epoxy composite material

Abstract

Carbon epoxy composite material is widely used in naval, aerospace, transportation, structural applications. Traditional machining of carbon epoxy composite is difficult due to improper surface features and kerf geometry, delamination, high tool wear, etc. In the present paper, research work involved in multi-performance optimization of abrasive water jet machining (AWJM) of carbon epoxy composite is described. Taguchi approach and analysis of variance are used to experimentally investigate the influence of process parameters on surface roughness and kerf taper. Four AWJM process parameters namely hydraulic pressure, traverse rate, stand-off distance and abrasive mass flow rate are considered for this study. It is found that two parameters, hydraulic pressure and traverse rate are most significant to control surface roughness and kerf taper. Analysis of scanning electron microscope images of machined surface of work-piece has been carried out to evaluate its microscopic features. The process is optimized for minimum surface roughness and kerf taper using Taguchi based grey relation analysis approach. Confirmation tests are carried out to verify improvement in the response characteristics using optimum set of AWJM process parameters.