Nickel alloys e.g. Inconel 718 have outstanding mechanical, thermal and corrosive properties. Despite its wide range of use Inconel 718 can still be considered as a hard to cut material using conventional cutting processes e.g. milling or turning. The abrasive waterjet (AWJ) technology has the capability to machine these hard to cut materials reliably with reduced mechanical and thermal damages at the same time. Being able to create notches with predictable depths, high aspect ratios and low predictable notch base irregularities via AWJ can lead to a substantial increase of machining performance of hard to cut materials. Thus, 3D near net shaping as a roughening process prior to conventional cutting processes is possible. The goal of this investigation was to analyze the correlation between AWJ settings parameters and the notch depth as well as the notch base irregularity when machining Inconel 718. A prediction model including the main effects, interactions and quadratic effects was developed using design of experiments.
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