Deepak Chandran Ganesh

The growing need to machine challenging materials, especially nickel-based superalloys found in vital aerospace and automotive parts, is evident. This study examines the machining of 15.5 mm Nimonic-263 superalloy using Abrasive Waterjet Machining (AWJM). Nine trial sets, repeated thrice, are comprehensively evaluated using an L9 orthogonal array design to analyze crucial machining variables: the impact of Stand-off Distance, Waterjet Pressure, and Traverse Speed on Kerf Angle, Machining Time, and Material Removal Rate. Statistical significance is evaluated through multi-parametric analysis of variance, and quadratic multiple linear regression models are formulated to correlate output responses with machining variables. The JAYA optimization algorithm is introduced to optimize the machining process, aiming to minimize Kerf Angle and Machining Time while maximizing Material Removal Rate. A comparison with Ant-Lion, Genetic, and Multi-Verse Optimization algorithms highlights JAYA’s effectiveness. A confirmation test validates the JAYA algorithm’s output, confirming its superior performance. This research aids in optimizing machining parameters for challenging materials, benefiting critical components in various industries, especially aerospace.

The demand for high-performance materials in aerospace, automotive, and power generation industries has led to the development and utilization of advanced superalloys. Nimonic C-263/263, a nickel-based superalloy, is widely employed in critical components of jet engines, such as combustion chambers, heat exchangers, reformer tubes, gas turbine power generation components like turbine discs, shafts, and blades, due to its exceptional high-temperature strength, corrosion resistance, and creep properties. However, the inherent hardness and toughness of this alloy pose significant challenges for conventional machining processes. Abrasive waterjet cutting (AWJC) emerges as a promising alternative for the efficient machining of such difficult-to-cut superalloy materials. This paper presents an in-depth investigation on the machinability of thick Nimonic 263 superalloy plate material using AWJC, aiming to provide insights into the effects of process parameters, cutting performances, and resulting surface integrity due to change in declination angle measurement. An examination was also conducted on the pattern of striation formation under varying process parameters, utilizing digital microscopic images. The goal of the study is to establish a link between the parameters of striation production and the angle of jet impingement. The results indicate that a decrease in striation during the water jet processing of Nimonic 263 superalloy is caused by an increase in the declination angle.