Abrasive water jet machining of carbon epoxy composite: Cutting performance, predictive models and optimization

Abstract

Carbon epoxy composite material has wide applications in naval and aerospace sectors. This paper describes an experimental study of abrasive water jet machining of carbon epoxy composite material. Cutting performance in terms of surface morphology, kerf formation and kerf wall features of machined samples have been studied to infer the basic mechanism of machining. Four process parameters namely hydraulic pressure, traverse rate, stand-off distance and abrasive mass flow rate have been considered. Design of experiments has been performed using response surface methodology and then based on experimental analysis predictive models have been developed to estimate surface roughness and kerf taper. It has been observed that jet pressure and traverse rate are the most significant parameters followed by abrasive mass flow rate and stand-off distance along with some quadratic and interaction terms to control kerf properties. Model predictions have been found in congruence with experimental values. Also, confirmation tests verify the experimental analysis. Further, a multi-response optimization has been performed on the basis of desirability function to improve kerf properties.