scholarly journals Material synthesis, characterization, and machining performance of stir cast beryllium copper alloy composites

2019 ◽  
Vol 43 (2) ◽  
pp. 143-152
Author(s):  
V. Sankar ◽  
R. Arravind ◽  
D. Manikandan
Keyword(s):  
Copper Alloy ◽  
Water Jet ◽  
Influential Factor ◽  
Machining Process ◽  
Machining Parameters ◽  
X Rays ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Beryllium Copper ◽  
Machining Properties

Copper alloys have important industrial roles due to their excellent properties. Beryllium copper is one of the copper-based alloys with the highest strength and excellent metal working and machining properties. Beryllium copper alloy composite is fabricated by the stir casting method. Its characteristics are studied with scanning electron microscopy and energy dispersive analysis of X-rays. The material properties of the stir cast beryllium copper alloy composites are evaluated. Hardness can be increased by the addition of silicon carbide particles. Abrasive water jet machining is an effective unconventional machining process, in which high pressure water jet and abrasive particles are used to remove material. Response parameters such as material removal rate and circularity of holes are considered. Response parameters of abrasive water jet machining are compared to electrical discharge machining. The most influential factor for the responses is determined by analysis of variance. Optimization of machining parameters is performed with the Taguchi method.

Study on carbon epoxy composite surfaces machined by abrasive water jet machining

2018 ◽  
Vol 53 (20) ◽  
pp. 2909-2924 ◽  
Author(s):  
Ajit Dhanawade ◽  
Shailendra Kumar
Keyword(s):  
Surface Roughness ◽  
Composite Material ◽  
Process Parameters ◽  
Surface Finish ◽  
Epoxy Composite ◽  
Water Jet ◽  
Machining Parameters ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Pull Out

Traditional machining of carbon epoxy composite material is difficult due to excessive tool wear, excessive stresses and heat generation, delamination, high surface waviness, etc. In the present paper, research work involved in the experimental study of abrasive water jet machining of carbon epoxy composite material is described. The aim of present work is to improve surface finish and studying defects in machined samples. Taguchi's orthogonal array approach is used to design experiments. Process parameters namely hydraulic pressure, traverse rate, stand-off distance and abrasive mass flow rate are considered for this study. Analysis of machined surfaces and kerf quality is carried out using scanning electron microscope to evaluate microscopic features. Further, the effect of machining parameters on surface roughness is investigated using analysis of variance approach. It is found that traverse rate and pressure are most significant parameters to control surface roughness. Optimization of process parameters is performed using grey relational analysis. Thereafter, confirmation tests are carried out to verify the improvement in the surface quality with optimum set of process parameters. It is found that surface finish of machined samples is improved by 10.75% with optimum levels of process parameters. Defects like delamination, fiber pull-out and abrasive embedment are also studied using SEM. It is observed that delamination and fiber pull-out are prominent in samples machined at low pressure and high traverse rate.

Sustainable Solution to Low-Cost Alternative Abrasive From Electric Ceramic Insulator Waste For Use in Abrasive Water Jet Machining

2021 ◽  
Author(s):  
Sabarinathan Palaniyappan ◽  
Annamalai Veiravan ◽  
Rajkumar Kaliyamoorthy ◽  
Vishal Kumar
Keyword(s):  
Performance Indicators ◽  
Value Added ◽  
Water Jet ◽  
Raw Material ◽  
Machining Process ◽  
Abrasive Water Jet ◽  
Machining Performance ◽  
Electric Insulator ◽  
Abrasive Water Jet Machining ◽  
Ceramic Insulator

Abstract Increasing demand and resource overuse has prompted the exploration of spent secondary materials as a primary raw material for a variety of applications, leading to a more sustainable environment. Spent electric grid ceramic insulator, one of the waste materials of ceramic industry has a good hardness and strength. It can be reused as value added material in Abrasive Water Jet Machining (AWJM) industry. This present work deals with conversion of electric insulator rejects (EIR) into a cost-effective replacement material for abrasive water jet machining process. Mechanical crushing method is opted to generate the abrasive grit for the machining process. Grit generation pattern and the friability of the electric insulator rejects were determined experimentally. The results indicate that the friability of the processed electric insulator rejects is comparable with the commercially available garnet abrasive. Geometric parameters such as sphericity, elongation ratio, and shape factor for the processed electric insulator rejects were studied using scanning electron microscopy. The machining performance indicators for standard aluminium material such as volume of material removal, kerf angle, surface roughness and cutting width were measured for electric insulator rejects and compared with existing garnet abrasive grain. The experimental results of newly generated electric insulator reject abrasive were matched with performance indicators of the garnet abrasive. The observed deviation was lower proving that it can be used as alternative abrasive in the abrasive jet machining process. Cost analysis and recycling ability predict the economical usability of the newly generated abrasives.

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