An investigation into cut surface quality of Al6061/Al2O3/B4C composite using hydro-abrasive machining process

The modern era has realized the tremendous potential of metal matrix composites (MMCs) in slowly substituting the traditional materials used in automotive and aerospace industries. Traditional machining of second generation MMCs is quite challenging due to heat generation, tool wear, and low cut surface quality. This work presents an analysis on hydro-abrasive machining (HAM) of the Al6061/Al2O3/B4C composite by using an amalgamated method of gray incidence based response surfaces (GIRS) to produce a good surface quality. The influence of HAM variables [abrasive flow rate (FA), waterjet pressure (PWJ), jet traverse speed (SJT), and stand-off distance (DS)] on various cut surface characteristics [surface roughness (Ra), striation-free zone (SFZ), striation angle (ΘS), and kerf angle (ΘK)] is examined using L27 OA and response surface plots. A hybrid approach of the GIRS method is presented for necessary polynomial modeling and simultaneous optimization. The reduction of response values is primarily influenced by the waterjet pressure and jet traverse speed. An optimal cutting condition resulted in a significant reduction in surface roughness by 19.22% and striation angle by 10.82%. The improvements in striation-free zone and kerf angle were also notable with reductions of 7.89% and 4.74%, respectively. FESEM images of machined surfaces, profile graphs of surface roughness, and images observed using atomic force microscopy were also studied.