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Among the metal matrix composite (MMC) materials, aluminum carbon fiber reinforced (Al-CF) composites are suitable for thermal management applications in fields, such as space, automobiles, etc. However, the application of Al-CF composite material is limited due to manufacturing difficulties, such as brittleness, non-uniform dispersion of fibers, and failure under low loads being a soft material. Challenges further increase in the case of producing thin-walled structures and features with a high aspect ratio ( e.g.  2D structures).In this study, an experimental investigation is carried out on the machinability of Al-CF composite material. The material response to AWJs is assessed by studying the kerf characteristics in through-cutting and analyzing the machined surface micrographs. From the results, it is observed that the kerf width and the erosion depth increase with the waterjet pressure ( P ) and abrasive mass flow rate ( m f), and decreased with the jet traverse rate ( v f). A minimum taper is obtained at low  m f and low  v f at an optimum  P . The material removal rate is maximum at high  P  and  m f at an optimum  v f. Based on this understanding, fabrication of a thin-wall (2D) structure with small features in Al-CF composite material is demonstrated by micro-AWJs.

advances in materials and processing technologies

Machining Thin-walled 2 1/2 D Structure in a Novel Aluminium Carbon Fiber Composite Material by the Micro-Abrasive Waterjets – an experimental investigation