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.

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.

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.

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.

scholarly journals Impact of Preparation of Titanium Alloys on Their Abrasive Water Jet Machining

Materials ◽  
2021 ◽  
Vol 14 (24) ◽  
pp. 7768
Author(s):  
Adam Štefek ◽  
Martin Tyč
Keyword(s):  
Titanium Alloys ◽  
Niti Alloy ◽  
Traverse Speed ◽  
Structural Features ◽  
Water Jet ◽  
Abrasive Water Jet ◽  
Abrasive Water Jet Machining ◽  
Declination Angle ◽  
The Impact ◽  
Awj Cutting

Several titanium alloys, i.e., grade 2 Ti, Ti6Al4V and NiTi alloy, prepared by selected deformation procedures were subjected to abrasive water jet (AWJ) cutting and subsequently analysed. The study describes samples’ preparations and respective material structures. The impact of deformation processing of the selected alloys on the declination angle during cutting, and the results of measurements of surface wall quality performed for the selected samples at the Department of Physics of Faculty of Electrical Engineering and Computer Science at VŠB–Technical University of Ostrava, are presented and discussed, as are also the influences of structural features of the processed titanium alloys on surface qualities of the investigated samples. The results showed that the highest resistance to AWJ machining exhibited the Ti6Al4V alloy prepared by forward extrusion. Its declination angle (recalculated to the thickness 10 mm to compare all the studied samples) was 12.33° at the traverse speed of 100 mm/min, pumping pressure of 380 MPa, and abrasive mass flow rate of 250 g/min.

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

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.

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.

A Study on Deviations of the Jet with Traverse Speeds on Different Materials in Pocket Milling Using Abrasive Water Jet Machining Process

2013 ◽  
Vol 372 ◽  
pp. 402-405 ◽  
Author(s):  
T.V.K. Gupta ◽  
J. Ramkumar ◽  
Puneet Tandon ◽  
N.S. Vyas
Keyword(s):  
Current Trend ◽  
Traverse Speed ◽  
Milling Process ◽  
Water Jet ◽  
Machining Process ◽  
Work Piece ◽  
Abrasive Water Jet ◽  
Pocket Depth ◽  
Tool Paths ◽  
Abrasive Water Jet Machining

The current trend in abrasive water jet machining process is getting focused on milling applications using this technique. Abrasive water jet machining (AWJM) process is a well defined process for cutting or part separation. The present paper reports on the geometry obtained in controlled depth milling process of different materials. The dimensions considered in this paper are the pocket depth and the change in the kerf profile. Experimental observations are made relating the kerf profile with traverse speed and the mechanical properties of the work piece material. Tool paths for obtaining the pocket of size 9 mm x 20 mm are generated in raster mode and machined using AWJM on materials of varying hardness and at different traverse speeds. It is observed that there is a significant change in the geometry of the kerf profile and also the depth of the pocket with speed in conjuction with the material hardness.

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).

scholarly journals Process parameters effect on material removal mechanism and cut quality of abrasive water jet machining

2013 ◽  
Vol 40 (2) ◽  
pp. 277-291 ◽  
Author(s):  
P. Jankovic ◽  
T. Igic ◽  
D. Nikodijevic
Keyword(s):  
Damage Mechanics ◽  
Water Jet ◽  
High Tech ◽  
Abrasive Water Jet ◽  
Machining Processes ◽  
Pull Out ◽  
Water Jet Cutting ◽  
Cut Surface ◽  
Conventional Machining

The process of the abrasive water jet cutting of materials, supported by the theories of fluid mechanics, abrasive wear and damage mechanics, is a high-tech technologies that provides unique capabilities compared to conventional machining processes. This paper, along the theoretical derivations, provides original contributions in the form of mathematical models of the quantity of the cut surface damage, expressed by the values of cut surface roughness. The particular part of this paper deal with the results of the original experimental research. The research aim was connected with the demands of industry, i.e. the end user. Having in mind that the conventional machining processes are not only lagging behind in terms of quality of cut, or even some requests are not able to meet, but with the advent of composite materials were not able to machine them, because they occurred unacceptable damage (mechanical damage or delamination, fiber pull-out, burning, frayed edges).

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