Influence of brown algae filler and process parameters on the surface roughness and MRR of jute fiber polymeric composite machined by abrasive water jet

Traditional manufacturing of polymeric composite leads to delamination. Implementing abrasive water jet machining (AWJM) presents a sustainable solution for shaping the polymeric composites, thereby eliminating the need to dispose of chemically contaminated waste. Brown microalgae, commonly found in aquatic environments, serve as viable additives for enhancing the properties of polymeric composites. This study entails the polymeric composite reinforced with jute fiber fabricated by modulating the weight percentages of brown algae powder by 0, 3, and 6 wt.% utilizing the hand layup procedure. The composites were formed and subsequently subjected to drilling by AWJ machining filled with brown algae. The experimental investigation was done to analyze the effect of AWJ parameters: water jet pressure (WJP), traverse speed (TS), and stand-off distance (SoD)—on the material removal rate (MRR) and average surface roughness (R_a). Orthogonal Array L₂₇ experimental results revealed that polymeric composite reinforced with jute fiber containing 3 wt.% of brown algae exhibited the highest MRR, with an increase of up to 12% compared to other samples. Additionally, these composites demonstrated a significant reduction in surface roughness, reaching up to 8% when compared to alternative samples. Utilizing the Taguchi-based ANOVA method facilitated a systematic exploration and identification of influential factors impacting both MRR and R_a in AWJ machining. Notably, the WJP and SoD emerged as key factors significantly influencing both MRR and R_a.