scholarly journals Optimization of Input Parameters of AWJM: Using three different Abrasives on MS2062

2019 ◽  
Vol 1 (1) ◽  
Author(s):  
Jasbeer Singh Satwant Singh Sidhu ◽  
Kusnurkar S. V
Keyword(s):  
Design Of Experiments ◽  
Aluminum Oxide ◽  
Analysis Of Variance ◽  
Flow Rate ◽  
Surface Finish ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Input Parameters ◽  
Kerf Angle ◽  
Taguchi’S Design Of Experiments

The objective of this work is to optimize input parameters of AWJM (Abrasive Water Jet Machining) such as Nozzle Transverse Speed (NTS), Abrasive Flow Rate (AFR) and Stand-off Distance (SOD) using three different abrasives Garnet, Brown Fused Alumina and White Aluminum Oxide on MS2062 and to compare their performance with surface finish, MRR and kerf angle. Experiments were conducted according to Taguchi’s design of experiments. Analysis of variance is conducted to investigate the influence of each parameter on responses Three controllable parameters of three levels are applied for determining the optimal responses The results revealed that NTS is a most significant factor for MRR among three abrasives followed by AFR and SOD, with regards to surface finish and MRR White Aluminum Oxide has emerged as a most strong abrasive followed by Brown Fused Alumina and Garnet. It is recommended, to achieve the better surface finish, less kerf angle and good MRR White Aluminum Oxide be used in place of Garnet which is mostly used by the industry today.

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.

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

2016 ◽  
Vol 232 (4) ◽  
pp. 690-704 ◽  
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.

Performance Study of LaPO4-Y2O3 Composite Fabricated by Sol-Gel Process Using Abrasive Waterjet Machining

2019 ◽  
pp. 143-161
Author(s):  
M. Uthayakumar ◽  
Balamurugan Karnan ◽  
Adam Slota ◽  
Jerzy Zajac ◽  
J. Paulo Davim
Keyword(s):  
Surface Roughness ◽  
Silicon Carbide ◽  
Material Removal Rate ◽  
Removal Rate ◽  
Sol Gel ◽  
Abrasive Water Jet ◽  
Lanthanum Phosphate ◽  
Abrasive Water Jet Machining ◽  
Sol Gel Process ◽  
Kerf Angle

This chapter presents an effective approach to assess the abrasive water jet machining of lanthanum phosphate reinforced with yttrium composite. A novel composite is prepared with the mixture of lanthanum phosphate sol and yttrium nitrate hexalate with a ratio of 80/20 by aqueous sol-gel process. Silicon carbide of 80 mesh size is used as abrasive. The effects of each input parameter of abrasive water jet machining are studied with an objective to improve the material removal rate with reduced kerf angle and surface roughness. The observations show that the jet pressure contributes by 77.6% and 45.15% in determining material removal rate and kerf angle, respectively. Through analysis of variance, an equal contribution of jet pressure (38.18%) and traverse speed (40.97%) on surface roughness is recorded. Microscopic examination shows the internal stress developed by silicon carbide which tends to get plastic deformation over the cut surface.

A Method to Reduce Milling Time for Ti-6Al-4V Alloy for Controlled Depth Milling Using Abrasive Water Jet Machining

2011 ◽  
Vol 383-390 ◽  
pp. 1764-1768 ◽  
Author(s):  
Vijay Kumar Pal ◽  
Puneet Tandon
Keyword(s):  
Flow Rate ◽  
Traverse Speed ◽  
Water Jet ◽  
Abrasive Water Jet ◽  
Surface Waviness ◽  
Feed System ◽  
Machining Processes ◽  
Machining Time ◽  
Abrasive Water Jet Machining ◽  
Conventional Machining

This Abrasive Water Jet Machining (AWJM) process is usually used to through cut materials which are difficult to cut by conventional machining processes. This process may also be used for controlled depth milling (CDM) of materials. This work primarily focuses on controlling the abrasive flow rate to reduce the time for machining the component. Here, an experimental setup is made with a modified attachment for abrasive feed system to machine for Ti-6Al-4V alloy. The work also investigates the surface morphology, tolerance on depth of machining and surface waviness for the modified setup. With change in mass flow rate of abrasive, the traverse speed is altered and its effects on the machining time are studied. It is observed that traverse speed is an important parameter in the case of CDM for AWJM. It is also shown that surface waviness can be reduced as traverse speed is increased by using modified abrasive feeding system.

Investigations on surface roughness and tribology of miniature brass gears manufactured by abrasive water jet machining

2017 ◽  
Vol 232 (22) ◽  
pp. 4193-4202 ◽  
Author(s):  
Thobi Phokane ◽  
Kapil Gupta ◽  
Munish Kumar Gupta
Keyword(s):  
Surface Roughness ◽  
Mass Flow Rate ◽  
Mass Flow ◽  
Flow Rate ◽  
Optimization Technique ◽  
Water Jet ◽  
Machining Parameters ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Particle Swarm Optimization Technique

Surface roughness parameters are important indicators for determining the operating performance, tribology behavior, wear and tear characteristics, and service life of engineered parts including gears. This article presents the investigation on surface roughness, and tribology and wear aspects of miniature brass gears manufactured by abrasive water jet machining. Experiments have been conducted based on Taguchi's robust design technique with L9 orthogonal array to machine external spur-type miniature gears of brass having 8.4 mm pitch diameter, 12 teeth, and 5 mm thickness. The effect of three important process parameters namely water jet pressure, abrasive mass flow rate, and stand-off distance on mean roughness depth of miniature gears are analyzed. Surface roughness is found to decrease with the increase in the water jet pressure and abrasive mass flow rate, and increases with the increase in the stand-off distance. Particle swarm optimization technique has been used for parametric optimization to minimize the surface roughness of miniature gears. Confirmation experiment conducted at optimized abrasive water jet machining parameters resulted in superfine surface finish with mean roughness depth value of 4.1 µm superior than the finish obtained by other advanced processes for brass gears. The investigated values of bearing area characteristics, skewness, kurtosis, and friction coefficient confirm the tribological fitness of the miniature brass gear machined at optimum abrasive water jet machining parameters.

scholarly journals Determination of critical operating and geometrical parameters in diesel injectors through one dimensional modelling, design of experiments and an analysis of variance

2017 ◽  
Vol 232 (13) ◽  
pp. 1762-1781 ◽  
Author(s):  
Francisco J Salvador ◽  
Marcos Carreres ◽  
Marco Crialesi-Esposito ◽  
Alejandro H Plazas
Keyword(s):  
Design Of Experiments ◽  
Mass Flow Rate ◽  
Analysis Of Variance ◽  
Mass Flow ◽  
Flow Rate ◽  
Control Volume ◽  
Geometrical Parameters ◽  
One Dimensional ◽  
Injection Process ◽  
Rate Profile

In this paper, a design of experiments and a statistical analysis of variance (ANOVA) are performed to determine the parameters that have more influence on the mass flow rate profile in diesel injectors. The study has been carried out using a one dimensional model previously implemented by the authors. The investigation is split into two different parts. First, the analysis is focused on functional parameters such as the injection and discharge pressures, the energizing time and the fuel temperature. In the second part, the influence of 37 geometrical parameters, such as the diameters of hydraulic lines, calibrated orifices and internal volumes, among others, are analysed. The objective of the study is to quantify the impact of small variations in the nominal value of these parameters on the injection rate profile for a given injector operating condition. In the case of the functional parameters, these small variations may be attributed to possible undesired fluctuations in the conditions that the injector is submitted to. As far as the geometrical and flow parameters are concerned, the small variations studied are representative of manufacturing tolerances that could influence the injected mass flow rate. As a result, it has been noticed that the configuration of the inlet and outlet orifices of the control volume, together with the discharge coefficient of the inlet orifice, among a few others, play a remarkable role in the injector performance. The reason resides in the fact that they are in charge of controlling the behaviour of the pressure in the control volume, which importantly influences injector dynamics and therefore the injection process. Variations of only 5% in the diameter of these orifices strongly modify the shape of the rate of injection curve, influencing both the injection delay and the duration of the injection process, consequently changing the total mass delivered.

scholarly journals Abrasive water jet machining of fly ash and metakaolin based geo-polymers

2020 ◽  
Vol 322 ◽  
pp. 01020
Author(s):  
Marimuthu Uthayakumar ◽  
Ponnambalam Balamurugan ◽  
Kinga Korniejenko ◽  
Szymon Gądek ◽  
Dariusz Mierzwiński
Keyword(s):  
Aqueous Solution ◽  
Fly Ash ◽  
Sodium Hydroxide ◽  
Sodium Silicate ◽  
Alkaline Solution ◽  
Water Pressure ◽  
Water Jet ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Input Parameters

In the present study, the abrasive water jet machining (AWJM) of geopolymers prepared from fly ash, metakaolin and sand is discussed. The samples were prepared from sodium promoter, fly ash / metakaolin and sand. The process of activation was made using a 10M sodium hydroxide solution combined with a sodium silicate solution (the ratio of liquid glass - 1:2.5). To produce geopolymers, flakes of technical sodium hydroxide were used and an aqueous solution of sodium silicate (R-145) with a molar module of 2.5 and a density of around 1.45 g/cm3 the tap water. The alkaline solution was prepared by means of pouring the aqueous solution of sodium silicate over the solid sodium hydroxide. The solution was mixed and left until its temperature stablised and the concentrations equalised, which took around 2 hours. The fly ash, sand and alkaline solution were mixed for around 10 minutes using a low-speed mixing machine (in order to obtain a homogeneous paste). The paste was allowed to dry in the shade. The paper investigates the AWJM studies on the prepared geopolymer specimens with varyied input parameters such as standoff distance (1.2 and 3 mm), water pressure (120, 140 and 160 MPa) and feed rate (5, 10 and 15 mm/min). The output parameters such as kerf angle and material removal rate (MRR) were studied with the varying combination of input parameters. From the results, the optimal parameters for machining the geopolymer composites were interpreted.

EXPERIMENTAL STUDY OF ABRASIVE WATER JET MACHINING OF KEVLAR EPOXY COMPOSITE

2019 ◽  
Vol 14 (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.

Experimental study of delamination and kerf geometry of carbon epoxy composite machined by abrasive water jet

2017 ◽  
Vol 51 (24) ◽  
pp. 3373-3390 ◽  
Author(s):  
Ajit Dhanawade ◽  
Shailendra Kumar
Keyword(s):  
Mass Flow Rate ◽  
Mass Flow ◽  
Process Parameters ◽  
Flow Rate ◽  
Epoxy Composite ◽  
Water Jet ◽  
Hydraulic Pressure ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Kerf Taper

The present article focuses on mechanism of delamination and kerf geometry in abrasive water jet machining of carbon epoxy composite. In the present study, four process parameters of abrasive water jet machining namely hydraulic pressure, traverse rate, stand-off distance, and abrasive mass flow rate are considered. The experiments are performed on the basis of response surface methodology as a statistical design of experiment approach. Delamination in machined samples is observed by using scanning electron microscope. Analysis of variance is performed in order to investigate the influence of process parameters on delamination, kerf taper ratio, and kerf top width. It is found that delamination decreases with increase in pressure and abrasive mass flow rate and decrease in stand-off distance and traverse rate. Kerf taper ratio decreases with increase in pressure and decrease in traverse rate and stand-off distance. Kerf top width decreases with decrease in stand-off distance and increase in traverse rate. Based on analysis, mathematical models are developed to predict the maximum delamination length, kerf taper ratio, and kerf top width. Further, a multi-response optimization is performed on the basis of desirability function to minimize delamination, kerf taper ratio, and kerf top width.

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