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Geometrical error in abrasive waterjet turned parts is an important challenge towards the abrasive waterjet turning process commercialisation. A Systematic study has not been done yet to investigate the effects of process parameters on geometrical error in abrasive waterjet offset-mode turning. In this paper, a comprehensive study has been performed to investigate the influence of several machining parameters on the geometrical error (part diameter percent error) in turning AA2011-T4 aluminum alloy round bars. Water pressure, cutting head traverse speed, workpiece rotational speed, abrasive mass flow rate and depth of cut were considered as the main machining parameters in a five levels statistical experimental design. Basing on central composite rotatable design (CCRD), a total of 52 experiments was carried out. The main effects of the parameters and interactions among them were analyzed based on the analysis of variance (ANOVA) technique and the response contours for the part geometrical error were obtained using a quadratic regression model (i.e. RSM). The model predictions were found to be in good agreement with experimental data. Furthermore, among the significant parameters, pressure, depth of cut and traverse speed are the most influential parameters, with percent contribution of almost 25% each. Abrasive mass flow rate places as the least influential parameter with a percent contribution of 4%.

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