A STUDY ON FABRICATION OF ABRASIVE WATER JET MACHINING PROCESS

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A STUDY ON FABRICATION OF ABRASIVE WATER JET MACHINING PROCESS Kumar Rahul Kenneth*1, Francis Rahul Charles*2 *1Student

of M. Tech, Production and Industrial Engineering, Vaugh Institute of Agriculture, Engineering and Technology, Mechanical Engineering Department, Sam Higginbottom University of Agriculture, Technology and Sciences, Prayagraj, India, P.O Box 211007.

*2Assistant

Professor, Mechanical Engineering Department, Vaugh Institute of Agriculture, Engineering and Technology, Sam Higginbottom University of Agriculture, Technology and Sciences, Prayagssraj, India, P.O Box 211007.

ABSTRACT Ultrahigh-pressure abrasive-water jets (AWJs) are being developed as net shape and near-net-shape machining tools for hard-to-machine materials. These tools offer significant advantages over existing techniques, including technical, economical, environmental, and safety concerns. Predicting the cutting results, however, is a difficult task and a major effort in this development process. The predictions of the A WJ cutting model are checked against a large database of cutting results for a wide range of parameters and metal types. Materials are characterized by two properties: the dynamic flow stress, and the threshold particle velocity. This research along these lines decides to sum up what's more, incorporate that previous exploration with that which has come to fruition as the innovation has moved into progressively far reaching mechanical use. Since water-jetting is currently utilized in a few extraordinary and particular zones where there might be no promptly evident traverse of enthusiasm between the undertakings. It has been conceivable to isolate the innovation into summed up however separate zones of utilization. The utilization of water jets under tension has gotten considerably more typical, in on-going years, for an expanding assortment of assignments.

Keywords:

I.

INTRODUCTION

Abrasive-water jets (AWJs) are formed by mixing abrasive particles with high-velocity water jets in mixing tubes as shown in Fig. 1. Conceptually, this technique is similar to that used in air-carried (or gascarried) abrasive-jets, which are conventionally used in abrasive-jet machining (AJM). With AWJs, however, larger quantities of abrasives can be accelerated to higher velocities to produce more coherent jets than typically used in AJM. The capabilities and applications of this technology are discussed elsewhere. The AWJ cutting process involves many parameters, including the following:          

Water jet pressure Water jet orifice diameter Mixing tube length Mixing tube diameter Abrasive material Abrasive particle size Abrasive flow rate Traverse speed Angle of cutting Material to be cut

An early investigation on useful uses of AWJM gave a far reaching rundown of potential applicant materials that were effectively machined. Instances of modern Utilizations of AWJM are found in machine instruments for AWJM have been broadly evolved in a few organizations throughout the previous two decades. A few machine devices’ structures are found in this www.irjmets.com

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paper is an audit of late improvements in AWJM research. An endeavour will be made to evaluate the current circumstance; to be specific, to discover what new information is accessible today, what is deficient in exploration and applications, and how the circumstance could be improved. The paper will focus on new examination discoveries acquired during the most recent two decades, which had created numerous helpful hypothetical just as trial discoveries. A great part of the examination has managed systems of material evacuation in various work materials, profitability and surface quality and a few surveys on AWJM have been led so far. Correlation contemplates, particularly among AWJM and laser, have likewise been led.

Fig. 1 Abrasive water jet nozzle concept 1.2 Water jetting Fundamentals Fundamental highlights of water stream use are basic both to new and more seasoned applications.

Exercises from one use can be learned and applied in improving plane execution in different applications.

Additional energizing, the manners by which a few types of water planes are utilized can be applied in different manners to discover new uses for this device, and permit forms which have not been conceivable without the advancement of this new type of intensity.

In any case, likewise with different types of intensity, it is anything but difficult to either utilize or abuse this new device, or to misconstrue those things which make it work. Therefore the content will examine the various perspectives which make up the framework, what causes these frameworks as powerful as they to can be, and what traps ought to be stayed away from in them. Be that as it may, before looking into any of those inquiries, one should initially choose what a water jet is Water without anyone else has compound and mechanical properties which make it valuable in various manners. While these properties might be changed in approaches to be talked about later for this content the water is the fate of more intrigue and worth when it starts to move. All the more especially when, as a moving stream of water, it is framed into a controlled jet of a predetermined shape. The most widely recognized type of such a water jet is a round stream of water which can be focused on some item so as to complete some work. In any event, when the water isn't moving quick it very well may be very successful.

1.3 What is a Water Jet ?

On the off chance that the majority of the air pockets can be made to crumple on the objective surface, at that point this will improve the cutting or cleaning capacity of the stream. This can be represented in two different ways. In cleaning gems and unpredictable little shapes it is conceivable to purchase little ultrasonic showers. The thing is set in the shower under a limited quantity of water. At the point when the force is turned on, the dividers of the shower vibrate ultrasonically. This causes exchange malleable and www.irjmets.com

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compressive waves to go through the water, making cavitation rises in the water, on the pressure stroke.

These are pushed against the thing and crumbled by the subsequent pressure, and the extremely little streams made hit the soil and surfaces of the gems. In view of this small scouring activity over the entire surface even the tight entries in incredibly unpredictable things can be cleaned by this technique expel the cleanser and grime from a vehicle.

1.4 Mechanics of Material Removal The fundamental components of material expulsion were concentrated widely and built up through exploratory just as logical work. The improvement of various wear components has pushed execution level of AWJM considerably further. An early disintegration model by water jets was created by Hashish and Du Plessis dependent on a control volume investigation to decide the hydrodynamic powers following up on the strong limits of the cutting opening. The coupled liquid strong mechanics conditions are improved to yield a shut structure arrangement which fulfills all the constraining states of reasonable cutting applications. Various materials were described by grating, damping and compressive yield quality.

Fig. 2 Cutting zones of abrasive water jet kerfs The early work of Finnie is still viewed as the main work, from that point forward various scientists in AWJM have built up a few cutting models on disintegration. Systems of disintegration of flexible materials ruled the writing until 1970. It is notable that there is an emotional contrast in the reaction of flexible and fragile materials to disintegration. Finne’s model for the forecast of material expulsion during disintegration of pliable materials was inferred by comprehending the condition of movement of a solitary molecule striking the surface at a shallow point.

Fig. 3. Erosion zones in AWJM www.irjmets.com

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II. 2.1.1

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MATERIALS

Materials used :-



Abrasive Material – Sand

  

Fabrication Material – Aluminium Fluid Used – Water Work-Piece Material – Granite

2.1.2 Applicable materials :            

Steels Non-Ferrous Alloys Ti Alloys, Ni Alloys Polymers Honeycombs Metal Matrix composite Ceramic Matrix Composite Concrete Stone – Granite Wood Reinforced Plastics Metal Polymer Laminates Glass Fibre Metal Laminates

2.1.3 Principle of Abrasive Water Jet Machine :The main principle of the machine is the basic principle of abrasive erosion. If a high terminal velocity of an abrasive particle hits on a hard or brittle work material, it removes some of the particles from the metal at the hitting surface. This metal removal process takes place due to brittle fracture of metal and also due to micro scoping cutting by abrasive particle.

2.1.4 Equipment’s used :a. Gas Propulsion System :- The main purpose of this system is to provide a clean and dry high velocity air for machining process. b. Abrasive Feeder :- It is a type of feeder which feeds abrasive particles through sieve which oscillates at about 50 – 60 hertz. c. Abrasive Material :- These are the major particles which holds an important role in the machining process. It has a rate of metal removal and accuracy. Mostly Aluminium Oxide , Silicon Oxide, Boron Carbide or Silicon Carbide based materials are used as an abrasive material. The selection process of the material is greatly dependent on the material of work piece , speed of machining and machining environment. d. Cutting Nozzle :- To guide the abrasive particle on the work piece a cutting nozzle is used which is made up of tungsten carbide. e. Machining Chamber :- The velocity of the particles are so high that it can easily harm any human body therefore to protect from such hazard machining chambers are used . It is equipped with a vacuum collector which collects abrasive particles and remove material from the mixing chamber.

Working Process : The basic process in the working of AWJM is abrasive erosion or metal cutting by high velocity abrasive particle. It can be explained as follows :

First the compressed air is send through an LP booster pump which intensifies the pressure of air.

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Next the air is send to a sand filtration unit since the dust and other suspended particles are removed from it as it may cause damage to the further units.

The cleaned air is then send to a drier where moisture is removed.

This air (dried) is then sent to a mixing chamber where abrasive particles are fed through a feeder and the air and particles gets mixed together.

This high pressure abrasive particle is then sent through a nozzle which through the kinetic energy gained from the air leaves the nozzle end by a velocity of 200m/s.

With a distance of 2mm between the nozzle and work piece the high velocity particles strikes the metals surface which through abrasive erosion scraps off the metal particles furthermore cutting it at a microscopic scale.

Fig 4. Set up of AWJM III.

MICRO – STUDY OF AWJM

The generally acknowledged clarification for the material science of the material expulsion process and the striation arrangement components for flexible and homogenous materials is that of Hashish who led an examination of the AWJ cutting procedure utilizing a rapid camera to record the material expulsion process in a plexiglass test. He found that the material expulsion process is a cyclic infiltration process that comprises of two cutting systems, which he named ''cutting wear zone'' and ''twisting wear zone'' following Bittar's erosive hypothesis.

Hashish likewise recommended that the cutting procedure comprises of three phases, which are the passage stage, the cyclic cutting stage and the leave stage. In the cutting wear zone, material evacuation is by rough particles striking the workpiece at shallow approaches while material evacuation in the distortion wear zone is by the grating particles impinging everywhere edges of assault. The general disintegration process continues in a cyclic way with consistent material evacuation up to a basic profundity hc followed by the development and expulsion of steps as the cutting profundity increments.

Beneath this basic profundity hc, the material evacuation process is flimsy, coming about in the arrangement of striations or waviness on the mass of the cut surface. Along these lines the difference in material evacuation process starting with one mode then onto the next is recommended to be the reason for striation or waviness. The material evacuation process in flexible materials is respected to be for the most part because of disintegration at shallow points what's more, plastic twisting everywhere edges.

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Fig. 5. Wear and deformation cutting proposed by Hashish 3.1Advantages and Disadvantages of AWJM :Advantages :    

High quality surface finish It can machine heat sensitive material It is free from any type of possible vibrations Initialization and setup cost is low in comparison to other non – traditional processes Thin section can be machined very easily

Disadvantages :    

Low rate of metal scrapping and particle removal Abrasive particles can get stucked into work piece easily Due to high corrosion the life of nozzle is limited to upto 30 hours Abrasive particles are non reusable It cannot be used for machining of soft and ductile materials

IV.

RESULT AND DISCUSSION

Through the investigations conducted we were able to conclude that Abrasive Waterjet machining Process can be implemented as a better alternative than its various non traditional counterparts.

Abrasive Waterjet machining can be used in almost any section of the industry leading to a greater emphasis on time and energy conservation with high efficiency rate. Surface harshness is one of the most significant models, which assist us with deciding how unpleasant a workpiece material is machined. In all the examinations it was discovered that the machined surface is smoother close to the stream entrance and progressively gets more unpleasant towards the stream exit. This is expected to the way that as the particles descends they free their active vitality and their cutting capacity decays. By investigating the exploratory information of all the chose materials, it has been discovered that the ideal choice of the four essential boundaries, i.e., water pressure, grating mass stream rate, spout navigate speed and spout stalemate separation are significant on controlling the procedure yields, for example, surface unpleasantness. The impact of each of these boundaries is examined while keeping the other boundaries considered in this examination as consistent. The following conversation utilizes the test information at the focal point of the cut for every example and the surface harshness is surveyed dependent on the middle line normal. www.irjmets.com

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4.1 Impact of the working factors on the kerf widths The exploratory information, introduced in Table 4.1 are plotted as per the standards of the Taguchi technique for introducing the impacts of working factors on the kerf widths. It can for the most part be expressed that a speed up brought about a reduction in the kerf width everything being equal. The adjustments in the kerf widths were all the more plainly found in the stones which are generally coarsegrained, while it indicated a comparative pattern in the kerf widths of the medium and fine-grained rocks.

This wonder might be related with the impinging plane vitality levels. The stream vitality is typically over the vitality that is required for the material expulsion before the impinging. When impinging, the jet starts to lose its vitality quickly with further increment in the navigate speed. The jet having lower vitality has practically immaterial impact on the material expulsion rate. This may prompt an abatement in the kerf width as is in the current investigation.

Table-1: Experimental layout for orthogonal array in clouding the operating variables, their levels and results Experiment No.

Operating Variables

Kerf Widths (responses/results)

T

M

D

P

S

R1

R2

R3

R4

R5

R6

R7

R8

R9

1

1

1

1

1

1

1.43

1.35

1.75

1.41

1.32

1.53

1.32

1.42

1.27

2

1

2

2

2

1

1.87

1.43

2.48

1.57

1.42

1.52

1.86

1.58

1.46

3

1

3

3

3

2

2.56

2.92

3.75

1.95

1.78

1.85

1.69

1.59

1.56

4

1

4

4

4

2

3.87

3.76

4.34

2.06

1.81

2.04

1.98

1.54

1.71

5

2

1

2

3

2

2.25

2.46

2.62

1.65

1.62

1.67

1.73

1.52

1.68

6

2

2

1

4

2

1.79

2.36

224

1.40

1.72

1.55

1.72

1.60

1.52

7

2

3

4

1

1

3.31

3.59

3.77

1.55

1.66

1.59

1.68

1.52

2.06

8

2

4

3

2

1

3.22

3.04

3.40

1.63

1.29

1.73

1.63

1.50

1.82

9

3

1

3

4

1

2.16

2.39

2.55

1.80

1.67

1.55

1.67

1.62

1.71

10

3

2

4

3

1

3.11

3.13

3.75

1.53

1.49

1.56

1.63

1.36

1.64

11

3

3

1

2

2

2.70

3.26

2.55

1.52

1.49

1.63

1.46

1.58

1.64

12

3

4

2

1

2

1.89

2.17

2.57

1.46

1.70

1.56

1.64

1.55

1.76

13

4

1

4

2

2

2.84

2.89

3.47

1.35

1.59

1.85

1.64

1.49

1.63

14

4

2

3

1

2

2.05

2.07

2.53

1.91

1.72

1.80

1.4

1.57

1.75

15

4

3

2

4

1

2.15

2.39

2.49

1.51

1.57

1.59

1.61

1.66

1.64

16

4

4

1

3

1

1.77

1.95

1.98

1.34

1.68

1.15

1.42

1.63

1.61

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Fig-5: Effects of the operating variables on the kerf width Table-2: Statistical correlation matrix of the kerf widths and rock properties X1 X1

1

X2

X3

X4

X5

X6

X7

X8

X10

X9

X11

X12

0.849 −0.744 −0.057 0.288 0.349 −0.236 0.048 −0.029 −0.678 0.813 0.863 0.926

X2 0.849

1

X3 −0.744 −0.360

−0.360 0.154 0.291 0.482 −0.305 −0.122 −0.114 −0.500 0.513 0.636 0.737 1

X4 −0.057 0.154 0.205

0.205 −0.444 −0.226 0.142 −0.109 −0.153 0.814 −0.899 −0.850 −0.711 1

X5 0.288 0.291 −0.444 0.464

0.464 −0.255 0.579 −0.937 0.710 −0.039 −0.415 −0.372 −0.38 2 1

X6 0.349 0.482 −0.226 −0.255 0.159 X7 −0.236 −0.305 0.142 0.579 0.188

0.159

0.188 −0.667 0.436 −0.455 0.147 0.292 0.025

1

−0.917 0.325 −0.615 −0.504 0.333 0.373 0.409

−0.917

1

X8 0.048 −0.122 −0.109 −0.937 −0.667 0.325

X10 −0.678 −0.500 0.814 −0.039 −0.455 −0.504

−0.667 0.829 −0.348 −0.426

0.322 −0.348

−0.667 1 −0.775

X9 −0.029 −0.114 −0.153 0.710 0.436 −0.615 0.829

−0.775

1

0.322 0.013 −0.154

X11 0.813 0.513 −0.899 −0.415 0.147 0.333 −0.348 0.370 −0.085 −0.733

1

0.910 0.894

X12 0.863 0.636 −0.850 −0.372 0.292 0.373 −0.348 0.293 −0.193 −0.698 0.910 Y

Y

1

0.860

0.926 0.737 −0.711 −0.382 0.025 0.409 −0.426 0.377 −0.242 −0.596 0.894 0.860

1

Table 3: Statistical results of the multiple regression model Model Independent variables

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Coefficient

Standard error

Standard error of t value estimate

Tabulated t value

F ratio

Tabulated

Determination

F ratio

coefficient (R2)

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Constant

10.4129

2.5601

X1 (%)

9.3843

1.5993

−0.3328

0.1060

−3.1385

X4

−0.0392

0.0092

−4.2415

X11 (mm)

−0.0232

0.0044

−5.2148

X2

(kN/m3)

0.0551

4.06721.75

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3.28

0.928

5.8677

Fig. 6 (a) Predicted kerf widths derived from the rock properties (b) Plots of the residue against the predicted values

V.

CONCLUSION

The major purpose of the article investigated is to give an overview of the machining technique of Abrasive Waterjet Technology. Various key aspects required the reader to understand the processing technique is covered. Through the investigations of other articles various citations are included stating about the high performance offered by this technique which can have universal applications in the industries.

Applications :   

It can be used in various unit operations such as drilling and cutting of hardened metals.

It can also be used to implement machining process on brittle and heat sensitive materials like quartz, glass, mica etc.

It is can also be used in the manufacturing of electronic devices It is used in the smoothening of small holes and critical areas in machine parts.

Operations that can be done through AWJM :     

Cutting Drilling Milling Surface Preparation, cleaning, coating removal Waterjet peening Waterjet forming

VI. [1] [2]

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[10] David A. Summers Waterjetting Technology 2009 Taylor & Francis Publications ISBN 419 19660 9 [11] Lemma, L. Chen, E, Siores, J. Wang Study of cutting fiber reinforced composites by using abrasive water – jet with cutting head oscillation 2002, IRIS, Australia\ [12] Boud, C.Carpenterb, J.Folkesa, P.H.Shipway Abrasive waterjet cutting of a titanium alloy: The influence of abrasive morphology and mechanical properties on workpiece grit embedment and cut quality 2010 [13] F.L Chen, E. Siores The effect of cutting jet variation on striation formation in abrasive water jet cutting 2001 [14] Fuat Kartal A review of the current state of abrasive water-jet turning machining method 2017 The International Journal of Advanced Manufacturing Technology volume 88, pages495–505(2017) [15] Cosansu and C. Cogun An investigation on use of colemanite powder as abrasive waterjet cutting (AWJC) 2012 Journal of Mechanical Science and Technology 26 (8) (2012) 2371 – 2380 [16] G Sonawane, R Bachhav Abrasive Water Jet Machining A Review 2015 IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 12, Issue 4 Ver. II (Jul. - Aug. 2015), PP 44-52

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