Effect of Abrasive Flow Rate in Milling with Abrasive Water Jet

2011 ◽  
Vol 110-116 ◽  
pp. 196-201 ◽  
Author(s):  
Vijay Kumar Pal ◽  
Puneet Tandon
Keyword(s):  
Flow Rate ◽  
Traverse Speed ◽  
Flaw Detector ◽  
Water Jet ◽  
Abrasive Water Jet ◽  
Feed System ◽  
Destructive Testing ◽  
Machining Processes ◽  
Machining Time ◽  
Ultrasonic Flaw

This Abrasive Water Jet Machining (AWJM) process is usually used to cut the materials which are difficult to cut by conventional machining processes. In this work, controlled depth milling (CDM) is done using AWJM. 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 stainless steel. 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 may also be altered and its effects on the machining time are controlled. This work also employs Non-destructive Testing (NDT) method i.e. ultrasonic flaw detector to find out internal defects and cracks in the milled material.

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.

scholarly journals Surface Topography Analysis of Mg-Based Composites with Different Nanoparticle Contents Disintegrated Using Abrasive Water Jet

Materials ◽  
2021 ◽  
Vol 14 (19) ◽  
pp. 5471
Author(s):  
Kumari Bimla Mardi ◽  
Amit Rai Dixit ◽  
Alokesh Pramanik ◽  
Pavol Hvizdos ◽  
Ashis Mallick ◽  
...  
Keyword(s):  
Surface Topography ◽  
Flow Rate ◽  
Water Pressure ◽  
Traverse Speed ◽  
Water Jet ◽  
Abrasive Waterjet ◽  
Maximum Height ◽  
Average Particle ◽  
Abrasive Water Jet ◽  
Metal Matrix Nanocomposites

This study investigated the effect of abrasive water jet kinematic parameters, such as jet traverse speed and water pressure, on the surface of magnesium-based metal matrix nanocomposites (Mg-MMNCs) reinforced with 50 nm (average particle size) Al2O3 particles at concentrations of 0.66 and 1.11 wt.%. The extent of grooving caused by abrasive particles and irregularities in the abrasive waterjet machined surface with respect to traverse speed (20, 40, 250 and 500 mm/min), abrasive flow rate (200 and 300 g/min) and water pressure (100 and 400 MPa) was investigated using surface topography measurements. The results helped to identify the mode of material disintegration during the process. The nanoindentation results show that material softening was decreased in nanocomposites with higher reinforcement content due to the presence of a sufficient amount of nanoparticles (1.11 wt.%), which protected the surface from damage. The values of selected surface roughness profile parameters—average roughness (Ra), maximum height of peak (Rp) and maximum depth of valleys (Rv)—reveal a comparatively smooth surface finish in composites reinforced with 1.11 wt.% at a traverse speed of 500 mm/min. Moreover, abrasive waterjet machining at high water pressure (400 MPa) produced better surface quality due to sufficient material removal and effective cleaning of debris from the machining zone as compared to a low water pressure (100 MPa), low traverse speed (5 mm/min) and low abrasive mass flow rate (200 g/min).

Experiments on Dicing Monocrystalline Silicon Wafer Using Micro Abrasive Water Jet

2011 ◽  
Vol 287-290 ◽  
pp. 2863-2868 ◽  
Author(s):  
Yu Yong Lei ◽  
Dai Jun Jiang ◽  
Ke Fu Liu ◽  
Pu Hua Tang
Keyword(s):  
Surface Roughness ◽  
Surface Quality ◽  
Silicon Wafer ◽  
Flow Rate ◽  
Feed Rate ◽  
Water Jet ◽  
Monocrystalline Silicon ◽  
Abrasive Water Jet ◽  
Feed System ◽  
Moving Jet

The experiments on dicing monocrystalline silicon wafer using micro abrasive water jet turning were performed. A specifically designed water jet machine tool with four axes was developed and a specially designed cutting head has developed, in which the inside diameter of orifice and focusing tube is f125 mm and f500 mm respectively, while the silicon carbide solid abrasives with average diameter of 25-100 mm was used. In order to control the flow rate of micro abrasives precisely, an abrasive feed system with auger mechanism driven by DC motor reducer was used. The diameters of monocrystalline silicon bars are around 50 mm. Two basic turning methods, i.e. turning with stationary jet and turning with moving jet were applied. The preliminary experimental results such as kerf width, wafer thickness, surface quality etc. were analyzed. It was found that micro abrasive water jet can be used to precisely turn brittle materials like monocrystalline silicon. The turned wafer with thickness of 1 mm above could be achieved. A thinner wafer less than 1 mm is difficult to obtain during experiments because of cracking or chipping. Experiments demonstrate that the wafer surface has macro stripping characteristics similar to linear cutting. It was observed that there is less waviness and smooth surface on the turned wafer when with moving jet. And it depends greatly on the water jet pressure, feed rate of the jet, rotation speed of silicon bar, abrasive particle size as well as flow rate of abrasive. The detailed analysis indicates that the surface roughness of turned wafer with moving jet is around Ra 1.5-5.6 μm, while that of turned wafer with stationary jet is around Ra6.3 μm, when other conditions are same. The results show that surface quality turning with moving jet is obviously better than that of stationary jet. Smaller surface roughness of turned wafer could be obtained when finer abrasive is used. The experiment shows also that the wafer is typically tapered with either the stationary jet or moving jet. There is a concave on the turned surface when feed rate of the jet is too low or dwell time is too long. This is attributed to the jet rebound from one face to the other. Therefore there is an optimizing rotational speed during turning. This study indicates that dicing mono crystalline silicon wafer using micro abrasive water jet turning has potential application in semiconductor industry.

Analysis of Stresses in CFRP Composite Plates Drilled with Conventional and Abrasive Water Jet Machining

2013 ◽  
Vol 763 ◽  
pp. 127-143 ◽  
Author(s):  
M. Saleem ◽  
Habiba Bougherara ◽  
L. Toubal ◽  
F. Cénac ◽  
Redouane Zitoune
Keyword(s):  
Fatigue Testing ◽  
Composite Plates ◽  
Water Jet ◽  
Image Correlation ◽  
Initial Surface ◽  
Abrasive Water Jet ◽  
Machining Processes ◽  
Static Tests ◽  
The Difference ◽  
Conventional Machining

The aim of this paper is to analyze the influence of two machining processes on the mechanical behaviour of composite plates under cyclic loading. For this purpose, an experimental study using several CFRP plates drilled with conventional machining and non-conventional machining (abrasive water jet) was carried out. Digital image correlation and static tests using an Instron 4206 tester were performed. In addition, infrared thermography (IR) and fatigue tests were also performed to assess temperature and damage evolutions and also the stiffness degradation. Fatigue results have shown that the damage accumulation in specimens drilled with conventional machining was higher than the abrasive water jet ones. Furthermore, the endurance limit for plates drilled conventionally was approximately 10% higher than those drilled with abrasive water jet. This difference was related to the initial surface integrity after machining induced by the difference in the mechanism of material's removal between the two processes. The difference in surface texture was responsible for the initiation of stress concentration sites as evident from IR camera’s stress analysis. This was confirmed by SEM tests conducted after a destructive sectioning of the specimens before fatigue testing.

Multiobjective Optimization Under Uncertainty in Advanced Abrasive Machining Processes via a Fuzzy-Evolutionary Approach

2015 ◽  
Author(s):  
Adel T. Abbas ◽  
Mohamed Aly ◽  
Karim Hamza
Keyword(s):  
Multiobjective Optimization ◽  
Process Variations ◽  
Water Jet ◽  
Cutting Conditions ◽  
Optimization Under Uncertainty ◽  
Benchmark Problems ◽  
Abrasive Machining ◽  
Machining Processes ◽  
Machining Time ◽  
Penalty Term

This paper considers multiobjective optimization under uncertainty (MOOUC) for the selection of optimal cutting conditions in advanced abrasive machining processes. Processes considered are water-jet machining, abrasive water-jet machining and ultra-sonic machining. Decisions regarding the cutting conditions can involve optimization for multiple competing goals; such as surface finish, machining time and power consumption. In practice, there is also an issue of variations in the ability to attain the performance goals. This can be due to limitations in machine accuracy or variations in material properties of the workpiece and/or abrasive particles. The approach adopted in this work relies on a Strength Pareto Evolutionary Algorithm (SPEA2) framework, with specially tailored dominance operators to account for probabilistic aspects in the considered multiobjective problem. Deterministic benchmark problems in the literature for the considered machining processes are extended to include performance uncertainty, and then used in testing the performance of the proposed approach. Results of the study show that accounting for process variations through a simple penalty term may be detrimental for the multiobjective optimization. On the other hand, a proposed Fuzzy-tournament dominance operator appears to produce favorable results.

Effect of Process Parameters on Depth of Penetration & Surface Roughness in Abrasive Waterjet Cutting of Copper

2019 ◽  
Vol 895 ◽  
pp. 301-306
Author(s):  
Keshav Kashyap ◽  
S. Srinivas
Keyword(s):  
Surface Roughness ◽  
Mass Flow Rate ◽  
Mass Flow ◽  
Process Parameters ◽  
Flow Rate ◽  
Traverse Speed ◽  
High Water ◽  
Water Jet ◽  
Abrasive Waterjet ◽  
Depth Of Penetration

This study evaluates the effect of process parameters on depth of penetration and surface roughness in abrasive waterjet (AWJ) cutting of copper. Full factorial experiments are carried out on trapezoidal blocks for each of the three abrasive particle sizes used. Experimental parameters - abrasive mass flow rate, water jet pressure and traverse speed are varied at three levels. Main effects and contributions of process parameters to depth of penetration and surface roughness is calculated. From the data, it is observed that, high abrasive mass flow rate, high water jet pressure and low traverse speed resulted in higher depth of penetration and a high abrasive mass flow rate, high water jet pressure and low traverse speed resulted in lesser Ra value. Using experimental data a statistical model for predicting depth of penetration & surface roughness is developed. Error between experimental and statistical values are compared to validate the statistical model. The maximum DOP of 49.32mm was observed at AMFR=405.4 g/min, P=300 MPa, TS=60 mm/min, MS=60 Mesh and minimum DOP of 4.27mm was observed at AMFR=200 g/min, P=100 MPa, TS=90 mm/min, MS=80 Mesh.

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.

Determination of vibration frequency depending on abrasive mass flow rate during abrasive water jet cutting

2014 ◽  
Vol 77 (1-4) ◽  
pp. 763-774 ◽  
Author(s):  
Pavol Hreha ◽  
Agáta Radvanská ◽  
Sergej Hloch ◽  
Vincent Peržel ◽  
Grzegorz Królczyk ◽  
...  
Keyword(s):  
Mass Flow Rate ◽  
Mass Flow ◽  
Flow Rate ◽  
Vibration Frequency ◽  
Water Jet ◽  
Abrasive Water Jet ◽  
Water Jet Cutting ◽  
Abrasive Water Jet Cutting

scholarly journals Micro-channel milling using abrasive waterjets and high pressure abrasive slurry jets

2021 ◽  
Author(s):  
Naser Haghbin
Keyword(s):  
High Pressure ◽  
Particle Velocity ◽  
Flow Rate ◽  
Water Jet ◽  
Machining Process ◽  
Micro Milling ◽  
Micro Machining ◽  
Abrasive Water Jet ◽  
Micro Channels ◽  
Entrained Air

Abrasive water jet technology can be used for micro-milling using recently developed miniaturized nozzles. This thesis develops methodologies to predict the shape of micro-channels milled using high pressure abrasive water jets, and presents a new high pressure abrasive slurry jet micro-machining process. Since abrasive water jet (AWJ) machining is often used with both the nozzle tip and workpiece submerged in water to reduce noise and contain debris, the performance of submerged and unsubmerged abrasive water jet micro-milling of channels in 316L stainless steel and 6061-T6 aluminum at various nozzle angles and standoff distances were compared. It was found that the centerline erosion rate decreased with channel depth due to the spreading of the jet as the effective standoff distance increased, and because of the growing effect of the stagnation zone as the channel became deeper. The erosive jet spread over a larger effective footprint in air than in water, since particles on the jet periphery were slowed much more quickly in water due to increased drag. As a result, the width of a channel machined in air was wider than that in water. It was also found that the erosive efficacy distribution changed suddenly after the initial formation of the channel. Then, a new surface evolution model was developed that predicts the size and shape of relatively deep micro-channels up to aspect ratios of 3 resulting from unsubmerged and iv submerged abrasive water jet micro-machining (AWJM) using a novel approach in which two different erosive efficacy expressions were sequentially applied. Since the channels produced by AWJM were found to be relatively wavy due to fluctuations in abrasive mass flow rate, a novel high pressure (water pump pressure up to 345 MPa) abrasive jet slurry micro-machining (HASJM) system was introduced by feeding a premixed slurry into the mixing chamber of a water jet machine with a micro-nozzle. Moreover, an existing model developed for AWJM abrasive particle velocities was modified and used to predict the particle velocity in HASJM, and then verified using a double disc apparatus (DDA). The HASJM system was then used to study the effect of entrained air in abrasive water jet micro-machining (AWJM) by performing experiments at the same particle velocity and dose for the two systems. The centerline waviness, Wa, of micro-channels made in SS316L and Al60661-T6 using HASJM were typically 3.4 times lower than those made with AWJM using the same dose of particles due to the more constant abrasive flow rate provided by the HASJM provided. The centerline roughness, Ra was approximately the same in both processes at a traverse velocity of Vt=4572 mm/min and a nozzle angle of 90°. For micro-channels of a given depth, the widths of those made with HASJM were 25.6 % narrower than those produced with AWJM, mainly due to the wider jet that resulted from the entrained air in AWJM.

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