The feasibility of using abrasive-waterjets (AWJs) for milling has been investigated in this research. The results of preliminary milling experiments indicate that abrasive-waterjets have great potential in this application with advantages unmatched by existing techniques. Linear cutting experiments were conducted on sample materials (aluminum, titanium, and Inconel) to generate a data matrix. The cutting results show a similar trend for these materials. The data were also correlated against a previously developed cutting model. Although a strong correlation is seen between the theoretical predictions and the experimental results, the prediction accuracy must be improved to allow for precision machining. Single-pass milling tests were also conducted to observe the geometry of the slots produced by the AWJ and the characteristics of the cut surface, and multipass milling tests were conducted on such materials as aluminum, glass, titanium, and graphite composites. Surface topography was found to be a function of both cutting and abrasive parameters, and surface finish was found to be strongly affected by abrasive particle size. A comparison with other machining techniques is presented in this paper. Abrasive-waterjet milling is among the most efficient methods of energy utilization for material removal.

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