Kerf Angle of Inconel 718 Under Non-Traditional Machining – Optimized Using Response Surface Methodology (RSM)

Machining Inconel 718 requires high dimensional accuracy due to its use in critical applications such as aerospace and power generation. Abrasive Water Jet Cutting (AWJC) offers a non-traditional alternative, utilizing high-pressure water mixed with abrasives for material removal. This study investigates the kerf angle of Inconel 718 under AWJC using Response Surface Methodology (RSM) with Box-Behnken Design (BBD). The effects of traverse speed (40% - 80%), abrasive mass flow rate (300 g/min - 800 g/min), and stand-off distance (5 mm - 15 mm) were analyzed. Results showed kerf angles ranging from 0.568º to 1.646º. ANOVA revealed that stand-off distance had the most significant influence, contributing 85.92% to kerf angle variation. Optimization suggested the minimum kerf angle (0.56º) is achievable at 40.57% traverse speed, 627.41 g/min abrasive flow, and 5.335 mm stand-off distance. Validation yielded a 3.11% error between predicted and actual results. These findings aid in optimizing AWJC processes for enhanced precision in Inconel 718 machining.