Comparative Analysis of AWJM Performance in FFF-Printed PLA and PLA–CF: Influence of Process Parameters and Cutting Regions

The fabrication of intricate polymer components through Fused Filament Fabrication (FFF) often necessitates post-processing to address inherent limitations in surface quality and dimensional accuracy. Abrasive Water Jet Machining (AWJM) presents a non-thermal post-processing solution, effectively enhancing the surface integrity of polymers and composites without inducing thermal damage. This research investigates the performance of AWJM on FFF-printed polylactic acid (PLA) and carbon-fiber-reinforced PLA (PLA-CF). The study systematically examines the impact of key process parameters, specifically water pressure (WP), traverse feed rate (TFR), and abrasive mass flow rate (AMFR), on machining outcomes. A comprehensive full factorial experimental design was employed to evaluate surface integrity, quantified by surface roughness (Ra) and kerf taper

(T). Analysis considered variations across distinct cutting regions: the initial damage region (IDR), smooth cutting region (SCR), and rough cutting region (RCR). Findings indicate that WP and TFR are the primary influential parameters, with AMFR exhibiting a constrained effect within the tested range. The smooth cutting region consistently demonstrated optimal surface roughness, while the rough cutting region showed notable degradation attributed to energy dissipation. Both PLA and PLA-CF exhibited comparable machining behaviors, with PLA-CF showing marginal improvements. Statistical analysis via ANOVA confirmed the predominant influence of process parameters over material type.

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