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Abstract This study investigates the influence of key process parameters – abrasive flow rate, traverse speed, material properties, and milling depth – on reducing machining time using abrasive waterjet machining (AWJM). A modified abrasive feed system was developed to explore the effects of mass flow rate changes on traverse speed and machining efficiency, revealing traverse speed as a critical factor in Controlled Depth Milling (CDM). Materials such as brass, AL 2024, AL 6061, AISI 304, titanium, and tool steel were tested, with findings showing that increased traverse speed reduces surface waviness. A novel “Machinability Index” was proposed to assess how material type affects milling time, with low-machinability materials requiring slower speeds. Surface roughness was predicted using a model based on solid particle erosion and jet penetration, which aligned well with experimental results. The study also examined abrasive waterjet trepanning for aerospace materials, analyzing parameters like pressure and traverse speed using a full factorial design. Empirical models were developed to understand their effects on kerf width, surface texture, and hole roundness. The research highlights the potential of integrating optical communication systems for real-time process monitoring and automation, enhancing precision and efficiency in advanced manufacturing environments.
Kumar et al. (Sat,) studied this question.