Title: Machinability study of hybrid epoxy/(BaTiO₃ + CaCu₃Ti₄O₁₂) composite in abrasive jet machining

Authors: Ajit Kumar Behera; Punyapriya Mishra; Trupti Ranjan Mahapatra; Punyatoya Mishra; Debadutta Mishra

Addresses: Mechanical Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Department of Physics, Parala Maharaja Engineering College (PMEC), Berhampur, Odisha, 761003, India ' Mechanical Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Department of Physics, Parala Maharaja Engineering College (PMEC), Berhampur, Odisha, 761003, India ' Mechanical Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Department of Physics, Parala Maharaja Engineering College (PMEC), Berhampur, Odisha, 761003, India ' Mechanical Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Department of Physics, Parala Maharaja Engineering College (PMEC), Berhampur, Odisha, 761003, India ' Mechanical Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Production Engineering Department, Veer Surendra Sai University of Technology (VSSUT), Burla, Odisha, 768018, India; Department of Physics, Parala Maharaja Engineering College (PMEC), Berhampur, Odisha, 761003, India

Abstract: This study explores the machinability of epoxy composites reinforced with barium titanate (BT) and calcium copper titanate (CCT) using abrasive jet machining (AJM). Composite samples were prepared by mixing BT and CCT in varying ratios (BT: CCT = 100:0, 40:60, 50:50, 60:40, 0:100) with an epoxy resin matrix (20:80) through compression molding. Mechanical properties, including density, microhardness, tensile, flexural, and impact strengths, were evaluated as per ASTM standards. While density decreased with increased CCT, hybrid composites demonstrated enhanced mechanical performance. AJM was conducted using silicon carbide abrasives, and machining parameters (filler proportions, pressure, stand-off distance) were optimised via Taguchi and ANOVA methods. Optimal settings improved material removal rate (RMR) by 2.041% and surface roughness (Ra) by 3.301%. Multi-response optimisation using Taguchi-based grey relational analysis achieved a 2.68% improvement in GRG values with the best results obtained at 5 bar pressure and 2 mm stand-off distance with CCT epoxy composite.

Keywords: epoxy-ceramic composite; ECC; barium titanate; BT; calcium copper titanate; CCT; Taguchi methodology; abrasive jet machining; AJM; grey relational analysis; GRA.

DOI: 10.1504/IJMMM.2025.150050

International Journal of Machining and Machinability of Materials, 2025 Vol.27 No.4, pp.320 - 344

Received: 14 Jun 2024
Accepted: 29 Aug 2024
Published online: 28 Nov 2025 *

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