Multi-response parametric optimisation of abrasive waterjet milling of Hastelloy C-276
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Multi‑response parametric optimisation of abrasive waterjet milling of Hastelloy C‑276 G. Gopichand1 · M. Sreenivasarao2 Received: 11 March 2020 / Accepted: 15 September 2020 © Springer Nature Switzerland AG 2020
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 (Ra). 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. Keywords Abrasive waterjet · Hastelloy C-276 · Pocket milling · Grey relational analysis · Surface morphology · Surface topography
1 Introduction A major issue in the manufacturing industry is the machining of high-strength materials including metals, non-metals, ceramics, composites, and nickel-based alloys. Abrasive waterjet (AWJ) machining is one among the promising methods for addressing the challenge owing to its applicability to a wide range of processes such as cutting, drilling, turning, and milling [1–4]. Among the various AWJ machining applications, pocket milling is one of the most important, involving the utilisation of the original concept of AWJ milling as a non-through cut industrial process. The extensive use of AWJ milling in industry has confirmed its
superiority to the conventional pocket milling process. The utilisation of AWJ milling method in the automotive and aerospace sectors, among others, has enabled the avoidance of some of the problems associated with conventional pocket milling [4–6], which include tool breakage, excessive tool wear, workpiece burnishing (due to tool dullness, too shallow cut depth, or too small radial relief angle), and the production of chatter marks (due to insufficient stiffness of the system and external vibration). In addition, and more specificall
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