Experimental investigation of the role of particle size and cutting passes in abrasive waterjet machining process on titanium alloy (Ti-6Al-4V) using Taguchi's method

The purpose of the research is to examine the process variables of the Abrasive Waterjet Machining (AWJM) on Titanium Alloy (Ti-6Al-4V). The input variables considered are abrasive mesh size, abrasive flow rate and the number of passes on the depth of cut. Other performance variables considered are material removal rate, taper angle and top kerf width. The experimental investigation is conducted for multi-pass machining using AWJM on Ti-6Al-4V. This investigation focuses on the effect of abrasive materials on the cutting profile of the machined workpiece cross-section, in which multiple pass cutting is found to have significant performance compared to single-pass cutting. The experiments are conducted using L27 Orthogonal Array using Taguchi's method and ANOVA analysis to find influential process variables, and the trend charts are plotted. Garnet is used in three different mesh sizes such as #60, #80 and #100 in this study. The varying abrasive flow rates and cutting passes are monitored to achieve the required cut profiles for the machining, which are further examined and analyzed. Machining at the higher abrasive flow rate gives a high value of cutting depth. It indicates that a minimum angle of taper obtained under a higher AFR and a larger size of abrasive particles. Optical Microscope and Scanning Electron Microscopic examination are done to explore the profile of the milling operation. Atomic Force Microscope is also used to validate the minimum surface roughness of the AWJM machined surface.