Comprehensive and essential review of advanced researches abrasive waterjet machining

Abstract

Abrasive Waterjet (AWJ) machining is a highly versatile non-conventional manufacturing technology, increasingly adopted across diverse industries due to its capability of processing a wide spectrum of materials, including metals, alloys, ceramics, composites, and polymers. Unlike conventional methods, AWJ utilizes high-pressure water mixed with abrasive particles to remove material by erosion, significantly reducing thermal effects, mechanical distortion, and material degradation. The performance and efficiency of AWJ machining are directly influenced by critical process parameters such as waterjet pressure, traverse speed, abrasive mass flow rate, stand-off distance, and nozzle geometry. Recent studies have shown that optimizing these parameters is essential to enhance surface finish, improve material removal rates, and reduce kerf defects such as taper angles and burr formation. This comprehensive review systematically synthesizes recent advancements and essential findings from the existing literature on AWJ machining. It emphasizes material-specific optimization strategies, explores critical interactions between machining parameters, and summarizes methodologies such as experimental designs, numerical modeling, response surface methodology, and artificial neural networks frequently used to optimize the AWJ process. Particular attention is given to identifying the underlying mechanisms influencing outcomes, such as material erosion phenomena, abrasive particle interactions with the material surface, crack initiation and propagation, as well as abrasive embedment. Furthermore, the review addresses current challenges, including achieving precision machining for hard-to-cut materials like superalloys (e.g., Inconel 718, Ti-6Al-4V) and fiber-reinforced polymer composites, highlighting recent solutions and future research directions. This extended synthesis provides valuable insights and standardized guidelines for industrial practitioners and researchers, facilitating broader adoption and continuous innovation within AWJ machining technology.