Experimental study on abrasive water jet machining of WCFC reinforced flax/wire mesh/hemp composite

Conventional machining of composite material was challenging due to delamination, tool wear, fiber pull-out, spalling, fiber fraying, heat generation, and excessive stresses. The non-conventional machining process was preferred for high-strength materials to produce complicated shapes with a better surface finish. This research describes an experimental analysis of abrasive water jet machining (AWJM) on flax/wire mesh/hemp reinforced epoxy composite. In addition, recycling of waste carbon fiber composite (WCFC) was also practiced and reused as a filler particle along with the fabricated hybrid composite. The hybrid composite was fabricated using the hand layup technique with 20.3 wt% of fiber, 10.5 wt% of wire mesh, and 2 wt% of WCFC. Experiments were conducted to evaluate the influence of standoff distance, traverse speed, and abrasive mass flow rate on the output responses such as kerf angle (θ) and surface roughness (Ra). The design of experiments found that surface finish was improved with optimum process parameters. It was detected that spalling defects, wear track, and micro-cutting were noteworthy in the machined hybrid composite concerning high standoff distance and abrasive mass flow rate. Morphological study in the cut surface of the hybrid composite was analyzed through a scanning electron microscope (SEM), and the fiber characterization was done through Fourier-transform infrared spectroscopy (FTIR).