A comprehensive literature review into the current state of abrasive waterjet (AWJ) machining technologies and the associated sciences has been conducted. It has revealed that AWJ milling possesses many traits which are desired by industry. However, little research has been devoted to its development and understanding the underlying material removal mechanism behind the machining process.Performance of AWJ milling, in formation of channels into amorphous materials was first investigated through an experimental investigation on brittle glasses. Macro-mechanism analysis has shown that channels are formed through four distinct erosion zones, each exhibiting characteristics connected to erosion mechanism and behavior of fluid flow in that zone. Bulge formation as a long-standing challenge of AWJ milling (27 years challenge) has been resolved through an in-depth understanding of the mechanism involved in the process. The analysis has revealed that material removal features, such as: material removal rate (MRR), depth of cut, and wall inclination angle can be reasonably controlled through proper selection of process parameters. Predictive models for material removal rate and other significant performance measures of the process have been developed, and experimentally verified.In second part, an innovative low-impact-angle milling method has been developed for machining AMM laminations for the first time in history of AWJ machining. Delamination as a major challenge of machining has been successfully overcome by designing and manufacturing a proper fixture assembly. Macro-mechanism analysis has revealed that produced channels exhibited a symmetric trapezoid shape cross-section. The analysis has revealed that material removal features, such as: material removal rate (MRR), depth of cut, wall inclination angle, top and bottom channel width can be properly controlled through suitable selection of process parameters. Predictive models have been developed for MRR and other significant performance measures of the process. The models have been experimentally verified and found to be capable of giving adequate predictions for the major channel geometrical features. Multi-objective optimization of the process has been conducted using Grey Relational Analysis (GRA) based on an orthogonal array. Its outcomes have enabled us to optimize multi-performance characteristics, where MRR and depth of cut have been maximized, and channel wall inclination angle has been minimized.This study has abundantly demonstrated machining capabilities of AWJ milling. Analysis into material removal processes has provided an in-depth understanding of the physical science associated with the technology, while the predictive developed models serve as a valuable basis for future process planning to effectively use the technology. The multi-objective optimization has prepared the developed technology further for the industrial applications.
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