Hybrid strategy for enhancing the dimensional accuracy and surface finish of abrasive waterjet milled pockets
DOI:
https://doi.org/10.58368/MTT.22.5.2023.30-35Keywords:
AWJ Milling, Conventional Milling, Hybrid Milling, Machine VisionAbstract
Abrasive waterjet (AWJ) milling of ductile material has advantages, such as negligible heat affected zone and no burr formation against conventional milling (CM). However, AWJ milling has limitations in terms of poor milled surface quality and not complying with the intended dimensions. To address this, in this work, a hybrid milling (HM) strategy is proposed where the major stock of material is removed by the AWJ, followed by a machine vision-based pocket dimensional measurement. By considering the deviations observed from the target, the shape and dimensions of the pocket are corrected by the CM. This work uses Al-6061-T6 alloy to demonstrate the HM strategy. The results from the HM strategy show that the vision approach accurately measured the dimensions of the AWJ milled pocket. The target pocket dimensions are maintained, the surface finish is enhanced from 3.20 µm to 0.55 µm, and the tool wear is reduced drastically.
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