A study on kerf characteristics of hybrid aluminium 7075 metal matrix composites machined using abrasive water jet machining technology

Abstract

Metal matrix composites are difficult to machine in traditional machining methods. Abrasive water jet machining is a state-of-the art technology which enables machining of practically all engineering materials. This article deals with the investigation on optimization of process parameters of abrasive water jet machining of hybrid aluminium 7075 metal matrix composites with 5%, 10% and 15% of TiC and B4C (equal amount of each) reinforcement. The kerf characteristics such as kerf top width, kerf angle and surface roughness were studied against the abrasive water jet machining process parameters, namely, water jet pressure, jet traverse speed and standoff distance. Contribution of these parameters on responses was determined by analysis of variance. Regression models were obtained for kerf characteristics. Contribution of traverse speed was found to be more than other parameters in affecting top kerf width. Water jet pressure influenced more in affecting kerf angle and surface finish. The microstructures of machined surfaces were also analysed by scanning electron microscopy. The scanning electron microscopy investigations exposed the plastic deformation cutting of hybrid 7075 aluminium metal matrix composite. X-ray diffraction analysis results proved the non-entrapment of abrasive particle on the machined surface.