Optimization of Abrasive Water Jet Machining Process Parameters on Onyx Composite Followed by Additive Manufacturing

Abstract

Fiber-reinforced additive manufacturing components have been used in various industrial applications in recent years, including in the production of aerospace, automobile, and biomedical components. Compared to conventional methods, additive manufacturing (AM) methods can be used to obtainin lighter parts with superior mechanical properties with lower setup costs and the ability to design more complex parts. Additionally, the fabrication of onyx composites using the conventional method can result in delamination, which is a significant issue during composite machining. To address these shortcomings, the fabrication of onyx composites via additive manufacturing with the Mark forged 3D-composite printer was considered. Machinability tests were conducted using abrasive water jet machining (AWJM) with various drilling diameters, traverse speeds, and abrasive mass flow rates. These parameters were optimized using Taguchi analysis and then validated using the Genetic algorithm (GA) and the Moth Flame Optimization algorithm (MFO). The surface morphology (Dmax) and the roughness of the drilled holes were determined using a vision measuring machine with 2D software (MITUTOYO v5.0) and a contact-type surface roughness tester. Confirmation testing demonstrated that the predicted values werenearly identical to the experimental standards. During the drilling of an onyx polymer composite, regression models, genetic algorithms and the Moth-Flame Optimization algorithm were used to estimate the response surface of delamination damage and surface roughness.