Materials Today: Proceedings xxx (xxxx) xxx

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Investigation and optimization for depth of cut and surface roughness

for control depth milling in Titanium Ti6AL4V with abrasive water jet
cutting
Yakub Iqbal Mogul a,⇑, Irfan Nasir b, Dr. Peter Myler c
a
School of Engineering and Computing, University of Bolton, RAK Academic Centre, United Arab Emirates
b
Mechanical Engineering, University of Bolton, RAK Academic Centre, United Arab Emirates
c
School of Engineering, University of Bolton, UK

a r t i c l e i n f o a b s t r a c t

Article history: Abrasive water jet (AWJ) cutting has been widely used in industries because of its precise cutting tech-
Received 11 September 2019 nique. However, the effectiveness of AWJ cutting is dependent on machine operating parameters and the
Received in revised form 17 October 2019 material properties. In this research AWJ cutting was applied on Titanium Ti6AL4V Grade 5 material to
Accepted 23 December 2019
investigate the effects on depth of cut (DoC) and roughness. Taguchi L27 experiments were conducted
Available online xxxx
at three levels with operating parameters such as water pressure, transverse speed, abrasive mass flow
rate, abrasive orifice size; a novel approach of ratio 3:1 was adopted with nozzle and orifice diameter
Keywords:
to accommodate more parameters for investigation and to inspect the variation of these parameters in
Control depth milling (CDM)
Abrasive water jet cutting (AWJC)
real time. Minitab 2017 software was used to simulate the influencing parameters with ANOVA. (GRA)
Titanium Grey relational analysis linked with Taguchi technique represents a novel approach to optimization. It
Ti6AL4V is a normalization estimation technique extended to elucidate the complex multi-performance character-
Grey relational analysis (GRA) istics. GRA is used for optimizing the process parameter which helped in determining the optimal param-
Roughness eters for roughness and depth of cut, ANOVA was used for analyzing the effect of independent variables
on dependent variables, as per ANOVA the P values and the S/N ration rank indicated that water pressure
was the most influencing parameter for surface roughness and transverse speed was the most influencing
parameter for the depth of cut. The prediction of cutting depth through GRA optimization proved a valu-
able tool for the controlled depth milling (CDM) in Ti6Al4V material.
Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International
Conference on Recent Advances in Materials & Manufacturing Technologies.

1. Introduction
Manufacturing industries are growing rapidly and becoming
one of the most important factors in global economy for growth.
In current era of industry 4.0 for smart manufacturing [18–20],
various innovative machining processes have been introduced
under the category of non-conventional machining providing
improved superiority machining while being competitively cost-
effective and efficient, including those based on plasma, EDM,
abrasive water jets (AWJ), lasers etc. AWJ machine is primarily
used to cut materials through and that are hard to cut by conven-
tional machining methods. These methods can be used to cut a
⇑ Corresponding author.
E-mail address: y.iqbal@bolton.ac.uk (Y.I. Mogul).
wide range of materials extending from soft materials like alu-
minium, and hard materials like Inconel, titanium, Kevlar, compos-
ites etc. [1] It is also used for (CDM) controlled depth milling of
materials. Hard to cut materials like titanium, kelvar and compos-
ites require a high precision and good knowledge of controlled
parameters of the machine because of the cost involved in the
material cutting, very high accuracy is required and when it comes
to control the depth of cut for these materials it becomes a chal-
lenge for the abrasive water jet machine to control the non-
linear parameters, very less research is available on the depth of
cut for Titanium 6AL4V Grade 5 material and milling being an
expensive and time consuming process in AWJ, there is a need to
investigate the parameters which are influencing the depth of cut
and roughness.

https://doi.org/10.1016/j.matpr.2019.12.229
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the 2nd International Conference on Recent Advances in Materials & Manufacturing
Technologies.

Please cite this article as: Y. I. Mogul, I. Nasir and P. Myler, Investigation and optimization for depth of cut and surface roughness for control depth milling
in Titanium Ti6AL4V with abrasive water jet cutting, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.12.229
2 Y.I. Mogul et al. / Materials Today: Proceedings xxx (xxxx) xxx

making [12] on titanium were investigated and surface roughness

Fig. 1. Influencing process parameters in AWJ cutting.
and quality of hole and time of drilling were investigated showing
a decrease in surface roughness by 25%.
Predicting the optimal parameters for a depth of cut and rough-
ness in any material with AWJ cutting is a complex process and a
challenge. As the number of levels and parameters are increased
for investigation the cost of experiments goes high and if the test-
ing materials are expensive it becomes a real challenge to select
the input parameters for investigation. Design of experiments
using Taguchi method makes the life of the researcher bit easier
[13,14]. Using Grey relational analysis (GRA) as an optimization
technique and a part of grey system theory proposed by Deng
[16] can solve problems with intricate interrelationships between
several factors and variables [15]. The proposed Taguchi-GRA
method has been used for optimization in many applications in
wire EDM, process parameter for submerged arc welding and man-
ufacturing. Very less research is seen with Titanium 6AL4V grade 5
materials for depth of cut with surface roughness and considering
this fact the current research attempts to investigate a novel
approach with Taguchi-GRA method involving six parameters with
two parameters as a ratio and variation with 3 levels for obtaining
the optimal parameters.

2. Methodology

In order to investigate the depth of cut and surface roughness

on Titanium Ti-6AL4V, current study considered water pressure,
transverse speed, abrasive flow rate, abrasive orifice size,
nozzle/orifice diameter ratio varying at low, medium and high
level considering the limitation of the machine operating parame-
ters, understanding the fact that orifice diameter and nozzle diam-
Fig. 2. Taguchi-GRA method flow chart.
eter wear with respect to machine operating hours both the
parameters were taken into consideration with a ratio of 3:1 con-
Table 1 sidering the variation in their diameters, this technique tallows
Design of experiment parameters and levels. more parameters to be varied during the experiment phase.
Factors Level Level Level
1-Low 2-Medium 3-High 2.1. Phase I – planning
Water pressure, bar 2400 2900 3400
Transverse speed, mm/min 80 100 150 Titanium Ti-6AL4V Grade 5 material 600  200  10 mm was
Abrasive mass flow rate, kg/min 0.160 0.180 0.215 considered for the experiment, for the design of experiment at
Abrasive orifice size, mm 3.8 4.0 4.2
Nozzle diameter ; mm 1:2 0:77 1:0
= 2.85 = 3.04 = 3.33
Orifice diameter; mm 0:25 0:35 0:30
(Ratio near 3:1)

Constant parameters: Stand of distance, SOD = 3 mm, Abrasive material = garnet 80

mesh, Angle of cutting = 90 deg, Number of passes = 1.

AWJ cutting is swayed by numerous process parameters such as

water pressure, abrasives, target work material and cutting param-
eters as shown in Fig. 1. Among them, certain parameters such as
abrasive flow rate, jet traverse speed, water pressure and standoff
distance are accurately controllable. Parameters such as the nozzle
diameter and orifice diameter changes constantly due to wear and
thus are uncontrollable [1–3]. Fig. 1 shows the influencing process
parameters in AWJ cutting in which water jet orifice diameter and
Fig. 3. Rectangular blocks through cut for roughness.
focusing nozzle bore diameter are nonlinear in their dimension
during the cutting process [4]. Various studies on the depth of
model [6,7] was carried out using nozzle oscillation techniques
and dimensional technique to understand the effects of parameters
on the depth of cut, it was establish that water pressure has the
greatest effect on the depth of cut. New techniques involving mod-
elling of incision profiles with rapid calibration and elementary
passes [8–10] were studies to understand the depth of cut, but
these techniques require lot of trials and require sophisticated
measuring instruments which add to the cost of investigation at
an initial stage itself. Studies on hole drilling [11] and deep hole Fig. 4. Slot cut for depth analysis.

Please cite this article as: Y. I. Mogul, I. Nasir and P. Myler, Investigation and optimization for depth of cut and surface roughness for control depth milling
in Titanium Ti6AL4V with abrasive water jet cutting, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.12.229
 Y.I. Mogul et al. / Materials Today: Proceedings xxx (xxxx) xxx 3

Table 2
Design of experiment, Taguchi L27 Experiments with measured output for roughness and depth.

Taguchi-L27 Experiment Measured Output

SR Water Pressure Transverse speed (mm/ Nozzle Diameter and orifice ratio Abrasive flow rate (kg/ Abrasive orifice size Roughness Depth
No (Bar) min) (mm) min) (mm) (lm) (mm)
1 2400 80 2.85 0.16 3.8 4.33 24
2 2400 80 2.85 0.16 4 3.94 14
3 2400 80 2.85 0.16 4.2 3.837 31
4 2400 100 3.04 0.18 3.8 5.72 9
5 2400 100 3.04 0.18 4 3.9 21
6 2400 100 3.04 0.18 4.2 4.727 8
7 2400 150 3.33 0.215 3.8 4.784 20
8 2400 150 3.33 0.215 4 4.891 17
9 2400 150 3.33 0.215 4.2 4.998 28
10 2900 80 3.04 0.215 3.8 4.723 21
11 2900 80 3.04 0.215 4 3.547 12
12 2900 80 3.04 0.215 4.2 3.643 27
13 2900 100 3.33 0.16 3.8 4.3 9
14 2900 100 3.33 0.16 4 4.62 18
15 2900 100 3.33 0.16 4.2 4.2 8
16 2900 150 2.85 0.18 3.8 4.183 19
17 2900 150 2.85 0.18 4 4.269 20
18 2900 150 2.85 0.18 4.2 4.292 21
19 3400 80 3.33 0.18 3.8 3.427 35
20 3400 80 3.33 0.18 4 3.73 22
21 3400 80 3.33 0.18 4.2 3.42 31
22 3400 100 2.85 0.215 3.8 4.307 12
23 3400 100 2.85 0.215 4 3.863 21
24 3400 100 2.85 0.215 4.2 3.867 8
25 3400 150 3.04 0.16 3.8 4.637 17
26 3400 150 3.04 0.16 4 3.527 9
27 3400 150 3.04 0.16 4.2 3.567 20

Fig. 6. Mitutoyo Surf test SJ-201P portable surface roughness tester.

Fig. 5. Experimental setup.

three levels and six factors were chosen with one as a combination
of a ratio to accommodate more varying parameters for the inves-
tigation as shown in Table 1. Minitab 17 was chosen for the statis-
tical analysis, Taguchi design of experiment with L27 half factorial
was considered, 27 experiments were performed on the AWJ
machine. In the initial experiments 27 rectangular blocks were
through cut as shown in Fig. 3 to understand the roughness and
the influencing parameters, More 27 experiments were conducted
for slot cutting with the same set of parameters along the thickness
to investigate the depth of cut as shown in the Fig. 4. Fig. 7. Depth measurement with Vernier Caliper.

Please cite this article as: Y. I. Mogul, I. Nasir and P. Myler, Investigation and optimization for depth of cut and surface roughness for control depth milling
in Titanium Ti6AL4V with abrasive water jet cutting, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.12.229
4 Y.I. Mogul et al. / Materials Today: Proceedings xxx (xxxx) xxx

Table 3
Grey Relational Analysis Results (GRA).

Input Step 1: Normalization Step 2: Deviation Step 3: Grey Relational Step 4: Grey
Data Sequence Coefficient Relational Grade
and Rank
Exp. No Ra (mm) Depth, m Ra (mm) Depth, m Ra (mm) Depth, m Ra (mm) Depth, m GRG Rank
1 4.33 0.024 0.604 0.593 0.396 0.407 0.558 0.551 0.555 11
2 3.94 0.014 0.774 0.222 0.226 0.778 0.689 0.391 0.540 13
3 3.837 0.031 0.819 0.852 0.181 0.148 0.734 0.771 0.753 3
4 5.72 0.009 0.000 0.037 1.000 0.963 0.333 0.342 0.338 27
5 3.9 0.021 0.791 0.481 0.209 0.519 0.706 0.491 0.598 10
6 4.727 0.008 0.432 0.000 0.568 1.000 0.468 0.333 0.401 26
7 4.784 0.02 0.407 0.444 0.593 0.556 0.457 0.474 0.466 20
8 4.891 0.017 0.360 0.333 0.640 0.667 0.439 0.429 0.434 25
9 4.998 0.028 0.314 0.741 0.686 0.259 0.422 0.659 0.540 12
10 4.723 0.021 0.433 0.481 0.567 0.519 0.469 0.491 0.480 17
11 3.547 0.012 0.945 0.148 0.055 0.852 0.901 0.370 0.635 7
12 3.643 0.027 0.903 0.704 0.097 0.296 0.838 0.628 0.733 4
13 4.3 0.009 0.617 0.037 0.383 0.963 0.567 0.342 0.454 24
14 4.62 0.018 0.478 0.370 0.522 0.630 0.489 0.443 0.466 19
15 4.2 0.008 0.661 0.000 0.339 1.000 0.596 0.333 0.465 21
16 4.183 0.019 0.668 0.407 0.332 0.593 0.601 0.458 0.529 15
17 4.269 0.01 0.631 0.074 0.369 0.926 0.575 0.351 0.463 22
18 4.292 0.021 0.621 0.481 0.379 0.519 0.569 0.491 0.530 14
19 3.427 0.035 0.997 1.000 0.003 0.000 0.994 1.000 0.997 1
20 3.73 0.022 0.865 0.519 0.135 0.481 0.788 0.509 0.649 6
21 3.42 0.031 1.000 0.852 0.000 0.148 1.000 0.771 0.886 2
22 4.307 0.012 0.614 0.148 0.386 0.852 0.565 0.370 0.467 18
23 3.863 0.021 0.807 0.481 0.193 0.519 0.722 0.491 0.606 9
24 3.867 0.008 0.806 0.000 0.194 1.000 0.720 0.333 0.527 16
25 4.637 0.017 0.471 0.333 0.529 0.667 0.486 0.429 0.457 23
26 3.527 0.009 0.953 0.037 0.047 0.963 0.915 0.342 0.628 8
27 3.567 0.02 0.936 0.444 0.064 0.556 0.887 0.474 0.680 5

Table 4 3. Experimental plan

Optimal parameters obtained from GRA technique.

Parameters
Water pressure
Transverse speed
Orifice size
Nozzle size
Abrasive flow rate
Abrasive orifice size
Roughness
Depth
2.2. Phase II – measurement
Roughness measurement was done with the Surf test SJ-201P
Roughness tester as shown in Fig. 6. For the slot cut depth mea-
surement was done with a Vernier caliper. Table 2 illustrates the
L27 orthogonal array of the performed experiments along with
the measured value of roughness and depth of cut
2.3. Phase III – optimization with grey relational analysis (GRA)
(GRA) Grey Relational Analysis combined with Taguchi
method represents a novel approach for optimization. It is a
normalization estimation technique extended to elucidate the
complex multi-performance characteristics. GRA is used in com-
bination with orthogonal array to draw implications about the
effect of the factor and their interaction on multiple responses.
Grey relational analysis is a type of method is used for optimiz-
ing the process parameter and helps in determining the optimal
parameters. Fig. 2 represents the methodology for Taguchi-GRA
method adopted.
Values AWJ machine for the experiment shown in Fig. 5 can produce a
3400 bar pressure of 4200 bar with a rated discharge of 3.6 ltr/min with
80 mm/min pump capacity 50 hp. The constant parameters were chosen as
0.30 mm stand of distance 3 mm, angle of cut 90 deg with single pass, the
1.0 mm abrasive material used was garnet with mesh size 80 for Titanium
0.18 kg/min
3.8 mm
6AL4V material for cutting, typically garnet signifies the highest
3.427 mm running cost on a AWJ machine, in order to minimize the use of
35 mm garnet reduction of orifice to focusing tube ratios are important
[5], for this three abrasive orifice sizes of 3.8 mm, 4 mm, 4.2 mm
is incorporated to understand the effect as shown in the Table 1.
Understanding the fact that orifice diameter and nozzle diameter
wear with respect to machine hours both the parameters were
taken into consideration with a ratio of 3:1 considering the varia-
tion in their diameters [17]. Surf test SJ-201P portable surface
roughness tester manufactured by Mitutoyo was used to deter-
mine the average surface roughness (Ra) on the cut material, Ver-
nier caliper was used to measure the slot depth along the
thickness of the material. Roughness measurements were taken
along the length and breadth as sown in Figs. 6 and 7 with their
mean values.
Designs of Experiments (DOE) were developed with Minitab 17
along with Taguchi L27 orthogonal array provided in Table 2 with
the measured values of roughness and depth for the 27 experi-
ments. For optimization grey relational analysis (GRA) was per-
formed, ANOVA was implemented for investigating the effect of
different parameters on roughness and depth.
Steps for Grey relational analysis GRA are shown below:
 Step 1: Normalize the value of roughness and depth
 Step 2: Calculate deviation sequence
 Step 3: Calculate Grey relational coefficient
 Step 4: Grey relational grade and ranking.

Please cite this article as: Y. I. Mogul, I. Nasir and P. Myler, Investigation and optimization for depth of cut and surface roughness for control depth milling
in Titanium Ti6AL4V with abrasive water jet cutting, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.12.229
 Y.I. Mogul et al. / Materials Today: Proceedings xxx (xxxx) xxx 5

Fig. 8. a: ANOVA results from Minitab 17 software for depth of cut (DoC). b: S/N ratio results from Minitab 17 software for depth of cut (DoC).

Table 3 shows the detail of the above four steps for the grey
relational analysis (GRA).
Optimal parameters are obtained from the Table 3 where rank 1
correspond to experiment no 19 which is highlighted for the opti-
mal parameters which shows lowest roughness and highest depth,
the optimal parameters are indicated below (Table 4).
4. Results and discussion
The Analysis of Variances (ANOVA) examines the implication of
the control factors and assesses the degree of their effects on the
response features by using Minitab as statistical modelling soft-
ware. Values of ‘‘Probability (P) > F” less than 0.05 indicate the
terms are significant with a confidence level of 95%.
4.2. Surface roughness, (Ra) analysis
It is observed from Fig. 10a that water pressure has the highest
effect on the surface roughness (P value = 0.003) followed by trans-
verse speed (P value = 0.014) and it can be verified from Fig. 10b
that rank 1 and 2 is associated with water pressure and transverse
speed.
Table 3 from experiment 19 indicates the highest roughness
value as 3.425 mm. From the main effect plot analysis for roughness
the parameters that are influencing most from highest to the low-
est are water pressure, transverse speed, nozzle to orifice diameter
ratio, abrasive orifice size and abrasive mass flow rate. The results
verified that an improvement of the surface roughness can be
achieved by increasing the water pressure at 3400 bar and low tra-
verse speed at 80 mm/min (Fig. 11).

4.1. Depth of cut (DoC) analysis

Fig. 8a indicate the responses for the depth of cut using Minitab
2017, As per ANOVA for S/N ratio it can be concluded that depth of
cut is influenced by transverse speed (P value = 0.014), followed by
abrasive mass flow rate (P value = 0.481), it can also be verified
from the Fig. 8b that the highest rank 1 is for transverse speed fol-
lowed by rank 2 for abrasive mass flow rate. From the main effect
plot Fig. 9, the influencing parameters from highest to the lowest
are transverse speed, abrasive mass flow rate, nozzle to orifice
diameter ratio, abrasive orifice size and water pressure and is
achieved from experiment 19 from Table 3 which confirms the
highest depth of cut with GRA grade and rank 1. The general phe-
nomena is that as the transverse speed increases the depth of cut
decreases due to the reason the impingement of the abrasive will
have very less time to erode the material at that particular instant,
However, the interaction between abrasive rate and feed rate is
important; to achieve a high depth of cut with lower feed rates
higher abrasive rates are needed. Fig. 9. Main effects plot for S/N ratio for depth of cut (DoC).

Please cite this article as: Y. I. Mogul, I. Nasir and P. Myler, Investigation and optimization for depth of cut and surface roughness for control depth milling
in Titanium Ti6AL4V with abrasive water jet cutting, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.12.229
6 Y.I. Mogul et al. / Materials Today: Proceedings xxx (xxxx) xxx

Fig. 10. a: ANOVA results from Minitab 17 software for roughness. b: S/N ratio results from Minitab 17 software for roughness.

experiments with AWJ machine and add to cost for the researcher,
variation considered in the nozzle and orifice diameter with a ratio
of 3:1 showed a good study to evaluate for real time changes in
these parameters. GRA optimization was used to convert a multi-
response problem into a single-response problem. It was seen from
the simulation that the most influencing parameters for the depth
of cut was transverse speed and for surface roughness is water
pressure.

6. Future scope of work

AWJ cutting being a complicated process and selecting the opti-

Fig. 11. Main effects plot for S/N ratio for roughness.
5. Conclusion
The investigation of this research proposed a combination of
GRA with Taguchi based design of experiments (DOE) for depth
of cut and roughness for Titanium 6AL4V Grade 5 materials which
is extensively used in many applications. The current research suc-
cessfully incorporated more parameters in the design of experi-
ments (DOE) which if taken individually will lead to more
mal parameters is a big challenge, under the current scenario if we
have a look at the 3 levels of all parameters the possibility of levels
between the 2 numbers are very high that means if any value of
any parameters are little bit changed the researcher need to again
perform experiments and it add to cost every time any parameters
are changed for investigation. For the future work researcher can
try to solve the above problem where any change in any parame-
ters can be deal with some sort of simulation method and did
not further require any more experiments to be performed, now
a day’s artificial intelligence (AI) with deep learning techniques
(Neural Nets) can be used with the help of high end software’s like
Matlab and Python and applying various algorithms to get the opti-
mized parameters.

Please cite this article as: Y. I. Mogul, I. Nasir and P. Myler, Investigation and optimization for depth of cut and surface roughness for control depth milling
in Titanium Ti6AL4V with abrasive water jet cutting, Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.12.229
 Y.I. Mogul et al. / Materials Today: Proceedings xxx (xxxx) xxx
Declaration of Competing Interest
[10]
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
[11]
to influence the work reported in this paper.
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