Improving the Machining Performance of Polymer Hybrid Composite by Abrasive Water Jet Machining for Precise Machining

Abstract

Natural fibre-reinforced hybrid polymer composites have gained significant attention worldwide in mechanical, aerospace, and automotive applications. Advanced machining techniques, such as abrasive water jet machining, have emerged as a solution to various challenges in this field, offering benefits such as the ability to shape complex geometries, achieve superior performance, improve surface characteristics, and attain high levels of accuracy. The research proposes a new approach for producing biodegradable hybrid composites composed of polylactic acid, bamboo particles, and montmorillonite clay using an innovative solvent-free stir-casting technique optimised for maximum efficiency. To systematically analyse the surface roughness, kerf angle, and material removal rate, a Box–Behnken design of experiments was employed, with the traverse rate, abrasive feed rate, and stand-off distance considered design variables. Analysis of variance was used to determine the significance of the differences between means of variables, while response surface methodology was utilised to establish the explicit relationship between the design variables and the response of the composite machining. The particle swarm optimisation algorithm was also employed to determine the optimal values of the design parameters for machining composites. The results showed that the traverse rate was the most influential factor, followed by the abrasive feed rate. In contrast, the stand-off distance had a relatively lower level of influence. The optimal process parameters were identified, resulting in a minimum surface roughness of 5.56 μm, a kerf taper of 0.0044 radians, and a material removal rate of 1175 g/min.