Investigation of cutting quality and surface roughness in abrasive water jet machining of bone

The abrasive water jet machining is known as a cold cutting process and can be effective for developing cut in the bone in orthopedic surgery to prevent thermal necrosis. This research examined surface roughness and cutting quality of bovine femur bone using abrasive water jet machining. Furthermore, the effect of three parameters was studied including water pressure, traverse speed, and the type of abrasive particles. The feed rate of the abrasive particles was considered 100 g/min, and the levels obtained from pure water jet cutting, bone powder abrasive water jet machining, and sugar abrasive water jet machining were compared with each other. Application of bone powder as an abrasive particle caused improved cutting quality, when compared with pure water jet, and in the best case, it resulted Ra and Rz values of 7.36 and 54.76 μm, respectively at the pressure of 3500 bar and traverse speed of 50 mm/min. The minimum surface roughness was obtained using sugar abrasive particles at the pressure of 3500 bar and traverse speed of 50 mm/min. The values of Ra and Rz parameters measured at the most desirable state were 3.87 and 19.72 μm, respectively. The results suggested that use of sugar as an abrasive material, in comparison with pure water jet and bone powder water jet, resulted in improved cutting quality. Furthermore, elevation of water pressure and reduction of traverse speed had a significant effect on improving surface roughness.

Download Full-text

A Study on Erosion of Alumina Wafer in Abrasive Water Jet Machining

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1017.228 ◽

2014 ◽

Vol 1017 ◽

pp. 228-233 ◽

Cited By ~ 1

Author(s):

Yong Wang ◽

Hong Tao Zhu ◽

Chuan Zhen Huang ◽

Jun Wang ◽

Peng Yao ◽

...

Keyword(s):

Process Parameters ◽

Water Pressure ◽

Abrasive Particle ◽

Particle Diameter ◽

Water Jet ◽

Abrasive Waterjet ◽

Abrasive Water Jet ◽

Alumina Ceramics ◽

Abrasive Water Jet Machining ◽

Jet Impact

Abrasive water jet machining is considered as a promising technique in hard and brittle material processing. This paper studies the erosion performance of the alumina ceramics in the different process parameters. In the erosion experiments, alumina ceramics wafers were eroded by the abrasive waterjet machining. The single factor experiments were carried out to understand the effect of different process parameters (jet impact angle, standoff distance, water pressure, abrasive particle diameter) on the material removal rate (MRR), the removal depth and surface roughness (Ra). The experimental results can provide guidance for alumina ceramics abrasive water jet cutting and polishing.

Download Full-text

Examination of Surface Roughness on Abrasive Water Jet Machining of Carbon Epoxy Composite

International Journal of Innovative Technology and Exploring Engineering - Special Issue ◽

10.35940/ijitee.b1062.1292s219 ◽

2019 ◽

Vol 9 (2S2) ◽

pp. 383-385

Keyword(s):

Surface Roughness ◽

Carbon Fibre ◽

Orthogonal Array ◽

Epoxy Composite ◽

Water Pressure ◽

Input Parameter ◽

Water Jet ◽

Abrasive Water Jet ◽

Taguchi Analysis ◽

Abrasive Water Jet Machining

The main aim of this investigation is to study the surface roughness produced on abrasive water jet machining of the twill weaved carbon fibre reinforced epoxy composite. Abrasive water jet machining experiment was conducted as per L9 orthogonal array, by varying water pressure, transverse speed and SOD. The performance of the composite was analysed by measuring the surface roughness. Using Taguchi analysis, the influences of input parameter over the output response was analysed. It was found that the surface roughness is highly influenced by the transverse speed.

Download Full-text

MODELING AND MULTI-RESPONSE OPTIMIZATION OF ABRASIVE WATER JET MACHINING USING ANN COUPLED WITH NSGA-II

Surface Review and Letters ◽

10.1142/s0218625x22500354 ◽

2022 ◽

Author(s):

ABHIMANYU K. CHANDGUDE ◽

SHIVPRAKASH B. BARVE

Keyword(s):

Water Pressure ◽

Traverse Speed ◽

Water Jet ◽

Abrasive Water Jet ◽

Ann Model ◽

Nsga Ii ◽

Data Set ◽

Abrasive Water Jet Machining ◽

Reinforced Plastic ◽

Artificial Neural Network Ann

This paper aims to develop a predictive model and optimize the performance of the abrasive water jet machining (AWJM) during machining of carbon fiber-reinforced plastic (CFRP) epoxy laminates composite through a unique approach of artificial neural network (ANN) linked with the nondominated sorting genetic algorithm-II (NSGA-II). Initially, 80 AWJM experimental runs were carried out to generate the data set to train and test the ANN model. During the experimentation, the stand-off distance (SOD), water pressure, traverse speed and abrasive mass flow rate (AMFR) were selected as input AWJM variables and the average surface roughness and kerf width were considered as response variables. The established ANN model predicted the response variable with mean square error of 0.0027. Finally, the ANN coupled NSGA-II algorithm was applied to determine the optimum AWJM input parameters combinations based on multiple objectives.

Download Full-text

Parametric investigation on surface roughness and hole quality of Ti metal hybrid fibers cored laminate (MFL) during abrasive water jet drilling

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/09544062211046902 ◽

2021 ◽

pp. 095440622110469

Author(s):

Munusamy Rajesh ◽

Rajkumar Kaliyamoorthy ◽

Ramraji Kirubakaran

Keyword(s):

Surface Roughness ◽

Water Pressure ◽

High Strength ◽

Traverse Speed ◽

Water Jet ◽

Drilling Process ◽

Abrasive Water Jet ◽

Hybrid Fibers ◽

Sem Images ◽

Delamination Factor

High-strength environment-friendly metal-fiber laminates (MFLs) are increasingly used for primary structures for various engineering applications. The surface roughness variation and delamination factor of a titanium (Ti) metal-cored basalt/flax fiber laminate were investigated during abrasive water jet drilling (AWJD). The present AWJD investigation is to establish the correlation of four important process independent variables of WJP—water jet pressure, TS—traverse speed, QMFR—abrasive mass flow rate, and SOD—stand-off distance to the delamination factor (Fd-top) and surface roughness (Ra) of drilled hole. Central composite design (CCD) of L29 orthogonal array was used to perform the experimental observations. The statistical approach (ANOVA) was employed to determine the contribution of individual AWJD parameters to drilling operation. It is identified from experimental results that the water jet pressure is the most predominant process parameter and its contribution on Fd-top and Ra were 74.28% and 72.48%, respectively. Increasing the water pressure from low (160 MPa) to its higher range (320 MPa) showed that the surface roughness and delamination factor were reduced irrespective of other drilling parameters. Increased water pressure provides enough kinetic energy for abrasive particles to facilitate a higher penetration potential during the drilling process. Scanning Electron Microscope (SEM) images show the machining-induced damages like ploughing marks, uncut fibers, ridges, craters, matrix smearing, and delamination on an abrasive water jet drilled surface of prepared MFL.

Download Full-text

EXPERIMENTAL STUDY OF ABRASIVE WATER JET MACHINING OF KEVLAR EPOXY COMPOSITE

Journal of Manufacturing Engineering ◽

10.37255/jme.v4i1pp026-032 ◽

2019 ◽

Vol 14 (1) ◽

Cited By ~ 1

Author(s):

Puneet Kumar ◽

Ravi Kant

Keyword(s):

Experimental Study ◽

Surface Roughness ◽

Mass Flow Rate ◽

Flow Rate ◽

Epoxy Composite ◽

Water Pressure ◽

Traverse Speed ◽

Abrasive Water Jet ◽

Abrasive Water Jet Machining ◽

Kerf Taper

The present paper describes an experimental study of abrasive water jet machining (AWJM) of Kevlar epoxy composite. Influence of process parameters namely stand-off distance, water pressure, traverse speed and abrasive mass flow rate on surface roughness and kerf taper is investigated. Taguchi orthogonal approach is applied to plan the design of experiments; and subsequent analysis of experimental data is done using analysis of variance (ANOVA). It is found that water pressure and traverse speed are most significant parameters followed by stand-off distance and abrasive mass flow rate influencing surface roughness and kerf taper. With increase in water pressure and decrease in traverse speed, kerf taper and surface roughness decreases.

Download Full-text

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

Journal of Composite Materials ◽

10.1177/0021998318807278 ◽

2018 ◽

Vol 53 (20) ◽

pp. 2909-2924 ◽

Cited By ~ 8

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.

Download Full-text

A study on kerf characteristics of hybrid aluminium 7075 metal matrix composites machined using abrasive water jet machining technology

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405416654085 ◽

2016 ◽

Vol 232 (4) ◽

pp. 690-704 ◽

Cited By ~ 21

Author(s):

KSK Sasikumar ◽

KP Arulshri ◽

K Ponappa ◽

M Uthayakumar

Keyword(s):

Electron Microscopy ◽

Metal Matrix Composites ◽

Metal Matrix ◽

Traverse Speed ◽

Water Jet ◽

Matrix Composites ◽

Abrasive Water Jet ◽

Abrasive Water Jet Machining ◽

Kerf Angle ◽

Scanning Electron

Metal matrix composites are difficult to machine in traditional machining methods. Abrasive water jet machining is a state-of-the art technology which enables machining of practically all engineering materials. This article deals with the investigation on optimization of process parameters of abrasive water jet machining of hybrid aluminium 7075 metal matrix composites with 5%, 10% and 15% of TiC and B4C (equal amount of each) reinforcement. The kerf characteristics such as kerf top width, kerf angle and surface roughness were studied against the abrasive water jet machining process parameters, namely, water jet pressure, jet traverse speed and standoff distance. Contribution of these parameters on responses was determined by analysis of variance. Regression models were obtained for kerf characteristics. Contribution of traverse speed was found to be more than other parameters in affecting top kerf width. Water jet pressure influenced more in affecting kerf angle and surface finish. The microstructures of machined surfaces were also analysed by scanning electron microscopy. The scanning electron microscopy investigations exposed the plastic deformation cutting of hybrid 7075 aluminium metal matrix composite. X-ray diffraction analysis results proved the non-entrapment of abrasive particle on the machined surface.

Download Full-text