Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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A Review on methods used to optimize Abrasive Jet Machining

parameters
K. Vijay Kumar a,⇑, T.S.A. Suryakumari a, V. Mohanavel b
a
Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences, Chennai 602 105, Tamil Nadu, India
b
Department of Mechanical Engineering, Chennai Institute of Technology, Chennai 600069, Tamilnadu, India

a r t i c l e i n f o a b s t r a c t

Article history: This review paper proposed different methods used to optimize Abrasive jet machining parameters for
Received 20 September 2020 different conditions. These techniques are used to find the best process parameters and Increased quality
Accepted 28 September 2020 results. Different input parameters are involved in abrasive jet machining for obtaining output parame-
Available online xxxx
ters like material removal rate and surface roughness. The removal of material will be done using mixture
of high pressurized air and water and by using some chemical substance. Taguchi approach, Analysis of
Keywords: variance (ANOVA), Response surface method are used to optimize the process parameters of the exper-
Taguchi method
imental work done by Abrasive Jet machining.
Abrasive jet machining
Material removal rate
Ó 2020 Elsevier Ltd. All rights reserved.
Process parameters Selection and peer-review under responsibility of the scientific committee of the Emerging Trends in
Response surface methodology Materials Science, Technology and Engineering.

1. Introduction fundamental methods. Box-Behnken design is one of the basic

Taguchi technique is used to optimizing process or input
parameters of AJM by involving in experimental design and
orthogonal array is used for evaluating output parameters. Taguchi
design contains Robust design, Concept design, Parametric design
and Tolerance design.
ANOVA is one of the formulated method for testing the depen-
dent variable means at some factor levels. Comparison of 2 or more
groups in terms of their population can be done by having data at
every interval by using analysis of variance(ANOVA). Analysis of
variance takes the mean of two or more factorial levels and tests
their hypothesis at different factor levels it compares the variable
means of the response to make factors as an important element.
Response Surface Methodology (RSM) is the method used to
optimize the process parameters of AJM. It is a set of formulated
methods that are useful for evaluating different problems where
several variables influence the response and this method is used
to modify the response by finding the relation between the vari-
ables and the response. It conducts some number of tests in which
some changes will be made to the input parameters to determine
the causes for the observed or output reaction modifications. The
core composite methods and the Box-Behnken methods are two
⇑ Corresponding author.
E-mail address: vijaykumarkurra9871@gmail.com (K. Vijay Kumar).
optimization, a type of solution surface design which will not con-
tain embedded factorial or fractional design.
1.1. Introduction to abrasive jet machining
Abrasive jet machining is one of the machining process where
the material can be removed from the workpiece by using water
or air as medium, so there will be no chance of developing shocks
and thermal stresses. Abrasive jet machining involves in different
applications like drilling holes on the work piece, cutting etc. Dif-
ferent abrasive particles are used for different conditions for
required output parameters. Carrier gas or air is used to carry the
jet of the abrasive particle. The high velocity stream of abrasives
is generated by K.E converted from pressure energy of carrier gas
or air and hence high velocity jet. Nozzles directs abrasive jet to
the work material at given conditions. The abrasive grain particles
are used to remove the material by different cutting actions. The
parameters which are involved in abrasive jet machining are noz-
zle diameter, abrasive particles, stand of distance. This machining
process is employed in cutting of different materials like different
types of composite materials fabricated using different reinforce-
ments at different percentages. Recently, structural and non-
structural components are manufactured by lightweight materials
like aluminum or magnesium alloys [1–10]. The process or input

https://doi.org/10.1016/j.matpr.2020.09.778
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the Emerging Trends in Materials Science, Technology and Engineering.

Please cite this article as: K. Vijay Kumar, T.S.A. Suryakumari and V. Mohanavel, A Review on methods used to optimize Abrasive Jet Machining parameters,
Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.09.778
K. Vijay Kumar, T.S.A. Suryakumari and V. Mohanavel Materials Today: Proceedings xxx (xxxx) xxx

Table 1
Input and observed parameters.

Process parameters Output parameters

Abrasive particles Material Removal Rate (MRR).
Carrier gas Surface roughness of the work piece
Abrasive jet Nozzle life.
Nozzle
Work material

parameters and the output or observed parameters are mentioned

in the below table 1.

2. Material removal rate based on taguchi approach

Madhu Keshav Sharma et al. [11] presented the Taguchi

approach to obtain optimal parameters of Abrasive water jet
machining parameters. The material used is aluminium alloy
6061. Taguchi technique is used to optimize the process parame-
ters of Abrasive jet machining. Discussed the influence of trans-
verse rate, surface roughness followed by the stand of distance.
By the results it was concluded that pressure affects the MRR the
most followed by Traverse speed and SOD respectively. Fig. 1. Fig. 2. SOD, TR vs MRR at 350 MPa PRESSURE.
reveals the SOD, TR vs MRR at 300 MPa Pressure and Fig. 2 reveals
the SOD, TR vs MRR at 350 MPa Pressure. Fig. 3 reveals the SOD, TR
vs MRR at 400 MPa Pressure. Fig. 4 reveals the SOD, TR vs MRR at
450 MPa Pressure. The experimental results based on Taguchi’s L16
orthogonal array are plotted below
Water Jet Machining Parameters – 1) Pressure in MPa
2) Stand of Distance (SOD) in mm
3) Transverse Rater (TR) in mm/s
Observed value – Material Removal Rate (MRR) in mm3/min
Different pressures involved in this process are 300,350,400 and
450 MPa.
G. K. Kiran Kumar et al. [12] conducted experiments on process
parameters optimization of AJM to get the response parameter-
swhich are MRR, Surface roughness and Kerf Width of the work
material. Discussed about Traverse velocity in the process as the
most significant factor on Material removal rate. SOD and flow rate
of abrasive particles also influence the output parameters. Stated

Fig. 3. SOD, TR vs MRR at 400 MPa PRESSURE.

Fig. 1. SOD, TR vs MRR at 300 MPa PRESSURE.
that Abrasive Flow Rate is the control factor for surface roughness
of the material. Work piece material used is INCOLONEL ALLOY,
having different compositions of nickel, iron and chromium. The
experimental results based on Taguchi’s L25 orthogonal array are
plotted below
Water Jet Machining Parameters – 1) Abrasive Flow Rate (AFR)
in gm/min
2) Stand of Distance (SOD) in mm
3) Transverse Rater (TR) in mm/min
Observed value – Material Removal Rate (MRR) in mm3/min
Fig. 5 reveals the TR, AFR vs MRR and Fig. 6 reveals the TR, AFR
vs MRR. Deepak Doreswamy, et al. [13] investigated about differ-
ent Abrasive jet machining parameters like stand of distance, pres-
sure, traverse velocity and abrasive particle size on kerf width
formed on the work material. Process parameters are optimized
based on the Taguchi technique and experiments are performed

2
K. Vijay Kumar, T.S.A. Suryakumari and V. Mohanavel
Fig. 4. SOD, TR vs MRR at 450 MPa PRESSURE.
Fig. 5. TR vs MRR.
by using orthogonal array L27 to obtain small kerf width on the
work material. The key effects of the process parameters, as well
as the interaction effects, were evaluated using Analysis of variance
to obtain kerf distance. Based on the obtained results the pressure,
stand of distance and the rate of feed have a significant impact on
the top kerf width and on its feed rate the kerf diameter share is
24.72 percent, 12.38 percent, respectively, and 52.16 percent.
Therefore, the morphological test is conducted on the samples
using a scanning electron microscope, which was machined at
optimized process parameters. It was found that process parame-
ters designed for the AWJ machined surfaces were free of
delamination.
P. P. Badgujar et al. [14] conducted experiments to optimize the
process parameters of Abrasive jet machining which are grain size
3
Materials Today: Proceedings xxx (xxxx) xxx
Fig. 6. SFR vs MRR.
of the abrasive material, pressure used for the process for machin-
ing the work piece. Taguchi technique is used for the design of
experiment and ANOVA is used to optimize the input parameters
followed by orthogonal array (OA) L27. In order to obtain low sur-
face roughness for the work material the controllable factors are
added to determine optimum mix of variables. The findings show
that the thickness of the abrasive content grain has a significant
influence on the SR. The results states that least possible number
of experiments gives the effectiveness of problem solving for a full
factorial design.
M. Sreenivasa Rao et al. [15] focused on process or input param-
eters (pressure of the water, stand of distance and traverse speed)
of Abrasive jet machining and also investigated the effect of these
parameters on surface roughness of mild steel. The process param-
eters are optimized using Taguchi approach and ANOVA. The out-
put parameters are formulated using orthogonal array(OA) L9 and
Taguchi technique is involved in DOE and stated that water pres-
sure, traverse speed and stand of distance as the most important
input parameters.
3. Literature review on response surface method and anova
D. V. Sreekanth et al. [16] implemented surface response
methodology on machiing of different materials by selecting pro-
cess parameters which are Stand of Distance, Nozzle Diameter
and Abrasive Flow Rate and MRR, KERF as response parameters.
The work material choosen for the study is Hastelloy C276 which
consists of Nickel-Chromium-Molybdenum as a combination. For
response parameters Regression equations were developed and
for machining response variable values were also identified.
K. Ravi Kumar et.al. [17] fabricated aluminum / tungsten car-
bide composites, studied about abrasive water jet machining
parameters. Investigations carried out on specimens carried out
through stir casting method and tungsten carbide reinforced com-
posite at different percentages. The methodology of the surface
response was used to investigate the influence of the abrasive jet
parameters and their answers ties. Scanning electron microscope
investigated the microstructure of the machined surfaces. The tra-
verse speed influences the MRR and percentage of tungsten carbide
influences the surface roughness of the work piece, stand of dis-
tance is the least significant parameter on both the output param-
eters. By varying the stand of distance, traverse speed and
percentage of tungsten carbide reinforced composite MRR is
K. Vijay Kumar, T.S.A. Suryakumari and V. Mohanavel
maximized and surface roughness is minimized. The experimental
results and multi-response optimization reached provide an auto-
motive technology scientific archive.
Dun Liu et al. [18] described about the impact of process param-
eters on penetration depth on surface roughness in abrasive turn-
ing of the water jet. The technique used in this analysis was the
Response Surface Technique (RSM) together with the Behnken
box architecture using transverse direction, strain, standoff dis-
tance, inclination angle, surface speed and abrasive flow rate as
operating parameters. The research work can be used primarily
to analyze the extent of aluminum ceramics ’ penetration and sur-
face roughness. Author concluded that transverse direction, along
with tilt angle, abrasive flow rate and pressure, is a very crucial fac-
tor on penetration depth (DOP).
J T Kavya et.al. [19] conducted experiments on refining and
evaluating important process parameters for Al7075-TiB2 metal
matrix composite abrasive water jet machining. The composite
Al-TiB2 metal matrix is synthesized using in-situ stir casting tech-
nique. The process parameters considered for the experimental
work are cutting speed, SOD, Abrasive Flow Rate which were taken
at five different levels and these parameters are designed using
Taguchi’s L25 Orthogonal approach. To determine the influence
of AJM parameters on different parameters like volumetric mate-
rial removal efficiency, dimensional precision and surface rough-
ness method of ANOVA is used. The testing confirmed that the
composite was fabricated successfully using AWJM according to
the design of experiments. The parameters like surface roughness,
dimensional roughness are calculated using the variance analysis
technique. Concludes that The parameters which affects the VMRR
are cutting speed(99.925%) followed by Stand of distance
(0.00721%) and Abrasive flow rate(0.0675%). The results shows
that cutting speed more impact on dimensional error compared
to SOD and AFR.
Mandal et.al. [20] conducted experiments on improving Abra-
sive Jet Machining method parameters using the Taguchi Process.
Pressure, width and angle of the nozzle stand between work piece
and tip of the nozzle were selected as input parameters and MRR
was selected as output parameter. Sand of silica with a grit size
of 600 lm was chosen as abrasive. The holes were built on carbon
material. Experiments were performed by choosing the L9 orthog-
onal array, and tests were analyzed using the Surface Reaction
technique. ANOVA is used to describe the parameters of important
systems. Statistical findings (at a confidence level of 95 per cent) in
the abrasive jet machining of glass composite state that the pres-
sure, angle between the work piece and the nozzle plane, and
Stand-off distance affects the metal removal rate respectively by
29.4%, 19.3% and 50.95%. The result shows that when stand-off dis-
tance is 15 mm by Taguchi’s optimization system the average
metal removal rate is 0.023 g / sec. Result obtained by ANOVA
notes that the most important process parameter is the Stand-off
size.
K. Umanath et al. [21] conducted experiments to inspect the
characteristics of the hybrid metal matrix composites. For fabrica-
tion purpose aluminium alloy Al6061-T6 was selected as a prime
matrix material, silicon carbide (SiC) and aluminium oxide
(Al2O3) were taken as reinforcement materials. The composite
was fabricated and preparation of samples done by stir casting pro-
cess. Silicon carbide and aluminium oxide were taken in equivalent
volume fraction. Scanning electron micrograph and x-ray diffrac-
togram were used to analyze the distribution of constituents and
it was observed that the scattering was uniform. ANOVA Technique
was used for the construction of experiments to complement the
procedure. The stimulus of wear test parameters has been investi-
gated and it has been detected that all the aspects have a signifi-
cant influence on the wear characteristic of these hybrid
composites
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Materials Today: Proceedings xxx (xxxx) xxx
Parteek et al. [22] researched about the abrasive grains of AJM
which hits the work piece at high pressure. This research deals
with the build and machining of the Abrasive Jet System on tem-
pered glass, the measurement of substance removal differs
between different performance parameters such as strain, abrasive
particle size etc. The experiments conducted on AJM are also dis-
cussed. Discussed about the problems occurred when machining
on tempered glass. For the analysis of MRR Taguchi approach and
ANOVA are used.
Vinod B et al. [23] found that the abrasive water jet machine
(AWJM) is a non-conventional method of mechanical base machin-
ing. Explained about the process of removing materials at varying
pressure, water velocity and greater abrasive grain strength which
will be focused on a piece of work. Experimental studies were car-
ried out to assess the influence of input parameters on observed
parameters (Material removal rate and surface roughness) of EN8
device parameters (AWJM). The methodology was based on the
Taguchi method and variance analysis (ANOVA) for maximizing
the parameters of the AWJM process for efficient machining.
Experiments are performed using L25 Orthogonal Array with vary-
ing values of input parameters on the work material.
4. Conclusion
This review paper contains research on different types of opti-
mization techniques i.e. Taguchi approach, Response Surface
Method, ANOVA which are used for optimizing the Abrasive Jet
Machining parameters. Based on the above research it can be con-
cluded that pressure is the most significant parameter for Material
Removal Rate other than remaining 2 input parameters. The best
parameters and increased quality results can be obtained by using
these techniques or methods by optimizing the AJM process
parameters.
CRediT authorship contribution statement
K. Vijay Kumar: Writing - original draft. T.S.A. Suryakumari:
Methodology, Formal analysis, Supervision, Validation. V. Moha-
navel: Formal analysis, Writing - review & editing.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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