Comparative performance investigation and sustainability evaluation between hot-AJM and AJM during machining of zirconia ceramic using Al2O3 abrasives

Machining of zirconia (ZrO2) ceramic is economically challenging due to its extreme hardness. Abrasive jet machining, distinguished by superior machining capabilities and the absence of thermal distortion, emerges as a highly competitive alternative to cutting processes involving plasma and lasers. This innovative research addresses a comparative performance evaluation and sustainability assessment between recently developed hot abrasive jet machining (hot-AJM) and traditional AJM of zirconia ceramic using aluminum oxide grain particles. The modified AJM employed abrasive air jet (combination of hot abrasive and compressed air) to strike on the work surface for material erosion. Briefly, the cutting performance is investigated by comparing the technological characteristics, namely material removal rate, machining cost, and machine tool vibration. Abrasive grain size, nozzle pressure, and stand-off distance are considered as the process variable for machining trials in accordance with design of experiments. Finally, a novel approach has been proposed for cost-saving economic analysis and sustainability assessment in order to rationalize the operational feasibility and usefulness of hot abrasives in AJM process with an intention to raise the awareness in the manufacturing industry. The use of hot abrasives in AJM improved material erosion due to the occurrence of plastic deformation followed by the deep chipping on the machined surface. From the results, it was observed that the hot-AJM outperformed the normal AJM with regard to improved material removal, reduced vibration, and minimal machining cost. Compared to normal AJM, machining under hot-AJM offered a better techno-economical viable to improve sustainability.