Multi-response parametric optimisation of abrasive waterjet milling of Hastelloy C-276

Abstract

Abrasive waterjet (AWJ) milling is a rapidly evolving research topic in the development of unconventional methods for machining high-strength materials without affecting their physical and thermal properties. It is considered as a promising technique for machining milling pockets in Hastelloy C-276. In the present study, the AWJ milling behaviour of Hastelloy C-276 was examined with the purpose of evaluating the performance parameters, namely the material removal rate and surface roughness (R a ). The considered input process parameters included the waterjet pressure, step over, traverse rate, and abrasive flow rate. The response surface methodology with a Box-Behnken design was used to perform the experiments, which involved 29 machining runs. Analysis of variance was used to identify the significant parameters of the machining process, and the optimal process parameter combination for achieving a high material removal rate and low surface roughness was established with the aid of response surface graphs. Multi-response optimisation based on grey relational analysis was also performed taking into consideration the overall output response. The waterjet pressure and traverse rate were identified as the primary determinants of the material removal rate, whereas the step over was the predominant factor of the surface roughness. The selected AWJ milling conditions based on grey relational analysis approach were examined using surface morphology, surface topography of milled pockets on Hastelloy C-276.

Determination of the Feasibility of Using Eco-Friendly Walnut Shell Abrasive Particles for Pocket Milling of Titanium Workpieces by Abrasive Waterjet Technology

“…This result indicates that the increase in particle velocity and the more intense interaction between the abrasives and workpiece surface can directly lead to increased material removal. Moreover, these findings are in accordance with the findings of previous works in the relevant literature, where it is underlined that jet pressure increases the momentum of the waterjet and subsequently the velocity of abrasive particles [45][46][47]. Thus, under higher jet pressure, it is easier to overcome the energy threshold for material removal [45].…”

Effect of Waterjet Cleaning Parameters During Paint Removal Operation on Automotive Steel Components

“…High overlap indicates that low step-over distance between adjacent cleaning passes. Because it increases the volume of the target material impinged upon per unit area of the impinging waterjet and, as a result, more uniform material removal process, a low step over results in a decrease in Ra[17]. The results of this study, however, demonstrate the opposite impact, which may be caused by the presence of abrasive embedment in AWJ, which increases surface roughness.…”

“…For a low pressure of 21 MPa in PWJ and AWJ, Surface roughness shows better value. It is possible to attain greater Ra values with lower waterjet pressures as a result of the optimum contact that is maintained with the workpiece, the high kinetic energy of the abrasive particles and, the homogeneous mixing that occurs within the chamber [17].…”

The effect of nozzle construction factors on hydraulic performance and prediction

“…Water jet technology has received a considerable lot of theoretical, practical, and numerical simulation study in recent years due to its benefits such as high efficiency, environmental protection, and simple resource acquisition 1 . Water jet technology is extensively used in industries such as coating removal [2][3] , cutting processing [4][5] , and impact rock breaking [6][7] , lotus root, and other crop mining fields 8 , and has produced significant social and economic benefits. The excellence of the nozzle construction influences the efficiency of its hydraulic performance.…”