This paper describes how optimization studies were carried out on an abrasive water jet (AWJ) cutting process with multiresponse characteristics based on Multi Criteria Decision Making Methodology (MCDM) using the Technique for Order Preference by Similarity Ideal Solution (TOPSIS) approach. The process parameters water jet pressure, traverse rate, abrasive flow rate, and standoff distance are optimized with multiresponse characteristics, including the depth of penetration (DOP), cutting rate (CR), surface roughness (R_a), taper cut ratio (TCR), and top kerf width (TKW). The optimized results obtained from this approach indicate that higher DOP and CR and lower R_a, TCR, and TKW were achieved with combinations of the AWJ cutting process parameters, such as water jet pressure of 300 MPa, traverse rate of 120 mm/min, abrasive flow rate of 360 g/min, and standoff distance of 1 mm. The experimental results indicate that the multiresponse characteristics of the AA5083-H32 unit used during the AWJ cutting process can be enhanced through the TOPSIS method. Analysis of variance was carried out to determine the significant factors for the AWJ cutting process.

This article investigates the 3D surface topography and 2D roughness profiles, and micrographs were analyzed in the abrasive water jet (AWJ) cutting of AISI D2 steel kerf wall cut surfaces by varying water jet pressures and jet impact angles. In 3D surface topography, roughness parameters such as Sq, Ssk, Sp, Sv, Sku, Sz, and Sa were improved by various jet impact angles with different water jet pressures. However, the roughness parameters Ssk and Sku strongly depend on the water jet pressure and jet impact angle. This is confirmed by kerf wall cut profile structures. Fine irregularities of peaks and valleys are found on the AWJ cut surfaces, as evident from 2D roughness profiles. The scanning electron microscope micrographs confirm the production of an upper zone not very much damaged and a lower striation free bottom zone, by using the jet impact angle of 70° with a water jet pressure of 200 MPa. Finally, the results indicate a jet impact angle of 70° maintaining the surface integrity of D2 steel better than normal jet impact angle of 90°. The results are useful in mating applications subjected to wear and friction. This has resulted in enhancement of the functionality of the AWJ machined D2 steel components.

In this study, end milling operations were conducted on Al 6082-T6 alloy by different cooling environments, cutting speeds or velocities (V_c), feed rates (f). The experimental results were statistically examined using the TOPSIS technique and the ANOVA test. Further, the effect of influencing process parameters, namely, cooling environment, feed rate, and cutting velocity on the various output responses, namely, cutting temperature (T_c), feed force (F_x), normal force (F_y), axial force (F_z) and average surface roughness (R_a) were studied. Tool wear and surface morphology, cut surfaces 2D and 3D profile investigation were performed to analyse the cut surfaces at various conditions. The ANOVA test output showed the cooling environment, f and V_c were the influencing cutting parameters affecting the different performance characteristics of end milling. The overall milling performance of the Al 6082-T6 alloy has been enhanced through proper selection of the optimal parameters setting, namely, wet cooling, f 0.02 m/tooth, and V_c 125 m/min by TOPSIS analysis.

Water jet peening is the unconventional surface treatment technique which is gaining importance in advanced manufacturing processes. In contrast to conventional peening operations, water jet peening acts as a simple process control, despite the presence of multiple variables in the process. This paper describes a pure water jet employed for impingement on the target surface of aluminium 6061-T6 alloy with a pure water jet cutting nozzle. In this study, experiments were conducted with different water jet pressure by varying the standoff distance, traverse speed and number of passes. Determination of the optimal water jet peening parameters for the aluminium alloy by the multi-response technique TOPSIS was another objective. The experimental results indicated improvement in the micro hardness and surface roughness of the peened surface over the base material. The compressive residual stress was measured for optimal setting conditions. No significant changes were observed in the water peened surface.