An Experimental Study of Radial-Mode Abrasive Waterjet Turning of Steels

2011 ◽  
Vol 697-698 ◽  
pp. 166-170 ◽  
Author(s):  
W.Y. Li ◽  
Jun Wang ◽  
Yasser M. Ali
Keyword(s):  
Experimental Study ◽  
Tilt Angle ◽  
Material Removal ◽  
High Surface ◽  
Machining Process ◽  
Radial Mode ◽  
Abrasive Waterjet ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Statistical Experimental Design

An experimental study of a radial-mode abrasive waterjet (AWJ) turning of AISI4340 high tensile steel is presented. The major process parameters, i.e. feed speed, waterjet pressure, abrasive flow rate, nozzle tilt angle, and workpiece surface speed, are considered in a statistical experimental design. The advantages of the radial-mode AWJ turning over the offset-mode turning include maximum jet energy utilization, high surface speed, a variety of nozzle tilt angles and small nozzle standoff distance, to enable high material removal rate (MRR). It is found that the depth of cut is considerably increased when large nozzle tilt angle and high surface speed are used. It also shows that feed speed and waterjet pressure are the two most significant parameters to control the MRR. This preliminary study suggests that the radial-mode AWJ turning is feasible and can yield high material removal rates. Future research to advance the knowledge about this new machining process is also proposed.

A Surface Roughness Model in Radial-Mode Abrasive Waterjet Turning for High-Tensile Steels

2013 ◽  
Vol 483 ◽  
pp. 177-181 ◽  
Author(s):  
Wei Yi Li ◽  
Hong Tao Zhu ◽  
Jun Wang ◽  
Chuan Zhen Huang
Keyword(s):  
Surface Roughness ◽  
Water Pressure ◽  
Steel Specimen ◽  
Machining Process ◽  
Radial Mode ◽  
Abrasive Waterjet ◽  
Average Error ◽  
Future Research ◽  
Feed Speed ◽  
Analysis Technique

Abrasive waterjet (AWJ) machining is an emerging machining method to process all kinds of difficult-to-cut materials. In this paper, a mathematical model for the surface roughness generated by a radial-mode AWJ turning process on a high-tensile steel specimen is developed using a dimensional analysis technique. To verify the model, a series of statistically designed experiments are carried out where feed speed, water pressure, abrasive flow rate, nozzle tilt angle, and workpiece surface speed are considered as variables. The model predictions are found to be in good agreement with the experimental results with the average error of 4.3%. Future research to advance the knowledge about this new machining process is also proposed.

Experimental Study of Machining of Smart Materials Using Submerged Abrasive Waterjet Micromachining Process

2018 ◽  
Author(s):  
Sagil James ◽  
Anurag Mahajan
Keyword(s):  
Experimental Study ◽  
Smart Materials ◽  
Thermal Stresses ◽  
Piezoelectric Materials ◽  
High Hardness ◽  
Machining Process ◽  
Critical Parameters ◽  
Abrasive Waterjet ◽  
Parameter Study ◽  
Wide Range

Smart materials are new generation materials which possess great properties to mend themselves with a change in environment. Smart materials find applications in a wide range of industries including biomedical, aerospace, defense and energy sector and so on. These materials possess unique properties including high hardness, high strength, high melting point and low creep behavior. Manufacturing of these materials is a huge challenge, particularly at the micron scale. Abrasive waterjet micromachining (AWJMM) is a non-traditional material removal process which has the capability of machining extremely hard and brittle materials such as glasses and ceramics. AWJMM process is usually performed with nozzle and workpiece placed in air. However, machining in the air causes spreading of the waterjet resulting in low machining quality. Performing the AWJMM process with a submerged nozzle and workpiece could eliminate this problem and also reduce noise, splash, and airborne debris particles during the machining process. This research investigates Submerged Abrasive Waterjet Machining (SAWJMM) process for micromachining smart ceramic materials. The research involves experimental study on micromachining of smart materials using an in-house fabricated SAWJMM setup. The effect of critical parameters including stand-off distance, abrasive grain size and material properties on the cavity size, kerf angle and MRR during SAWJMM and AWJMM processes are studied. The study found that SAWJMM process is capable of successfully machining smart materials including shape memory alloys and piezoelectric materials at the micron scale. The machined surfaced are free of thermal stresses and did not show any cracking around the edges. The critical process parameter study revealed that stand-off distance and abrasive grit size significantly affect the machining results.

Experimental study on the surface roughness of micromilled Elgiloy™

2011 ◽  
Vol 225 (11) ◽  
pp. 2138-2143 ◽  
Author(s):  
P Zhang ◽  
B Wang ◽  
Y Liang ◽  
M J Jackson
Keyword(s):  
Experimental Study ◽  
Surface Roughness ◽  
Surface Topography ◽  
Industrial Applications ◽  
Depth Of Cut ◽  
Mean Deviation ◽  
Machining Accuracy ◽  
Feed Speed ◽  
3D Surface ◽  
Axial Depth

Elgiloy™ is a cobalt-based alloy with excellent physical and chemical performance, and is used widely in medical and industrial applications. The machining accuracy, surface topography, and surface damaged layer play an important role in the use of the alloy for specific applications. In this paper, an experimental study on the surface roughness of precision micromilling of Elgiloy is accomplished by using a super-fine-grained tungsten carbide milling cutter. The surface topography of the surface of the slots milled is achieved with different values of feed speed and axial depth of cut. Three-dimensional (3D) measurement results are considered to reflect the surface topography based on a comparison of the difference between two-dimensional (2D) and 3D surface roughness measurements. The arithmetic mean deviation of the slots’ 3D surface is achieved by using a white light interferometric profilometer. By using analysis of variance (ANOVA), the factors of feed speed, axial depth of cut, and their interaction are proven to be the most important factors relating to the magnitude of surface roughness.

scholarly journals Multi-Objective Process Parameter Optimization for Surface Roughness and Material Removal Rate in Face Milling of Al 6061 T6 Alloy

2019 ◽  
Vol 9 (2) ◽  
pp. 137-142
Keyword(s):  
Surface Roughness ◽  
Process Parameters ◽  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Face Milling ◽  
Machining Process ◽  
Depth Of Cut ◽  
Al 6061

This study uses Taguchi methodology and Gray Relational Analysis approach to explore the optimization of face milling process parameters for Al 6061 T6 alloy.Surface Roughness (Ra), Material Removal Rate (MRR) has been identified as the objective of performance and productivity.The tests were performed by selecting cutting speed (mm / min), feed rate (mm / rev) and cutting depth (mm) at three settings on the basis of Taguchi's L9 orthogonal series.The grey relational approach was being used to establish a multiobjective relationship between both the parameters of machining and the characteristics of results. To find the optimum values of parameters in the milling operation, the response list and plots are used and found to be Vc2-f1-d3. To order to justify the optimum results, the confirmation tests are performed.The machining process parameters for milling were thus optimized in this research to achieve the combined goals such as low surface roughness and high material removal rate on Aluminum 6061 t6.It was concluded that depth of cut is the most influencing parameter followed by feed rate and cutting velocity.

scholarly journals Improve the Material Removal Rate of Electrochemical Grinding on Monel 400 Using RSM

2019 ◽  
Vol 8 (2) ◽  
pp. 3219-3222
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Electrochemical Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Grinding Wheel ◽  
Mechanical Grinding ◽  
Monel 400 ◽  
Electrochemical Grinding

Electrochemical grinding is combination of electrochemical machining and mechanical grinding process.in this process 90%-98% percentage of material are removed by electrochemical machining, only 3%-5% of materials can only remove by mechanical grinding process. Faradays law of electrolysis (or) reverse electroplating act as a basic principle for this ECG process. This ECG has various advantages than other machining process for high strength materials .low induvial stress, large depth of cut .here Monel 400 alloy take base material ,its Ni-Cu alloy so it’s have very high level corrosion resistance, so it’s used in marine engineering ,heat exchanger. Here silicon carbide abrasive insulated brass grinding wheel used instead of copper bonded diamond wheel. Voltage, electrolyte concentration, electrolyte flowrate take are the parameters of this process. Three factors and two levels of RSM methodology takes for optimization. The Analysis of variance (ANOVA) has been delivers the variation between the parameters performed to develop mathematical model. The parameters high voltage and concentration of electrolyte to produce maximum material removal rate.

Experimental Study on Machining of Hybrid Composite Stacks Using Submerged Abrasive Waterjet Machining Process

2018 ◽  
Author(s):  
Mayur Narkhede ◽  
Sagil James
Keyword(s):  
Experimental Study ◽  
Grain Size ◽  
Hybrid Composite ◽  
Machining Process ◽  
Critical Parameters ◽  
Abrasive Waterjet ◽  
Precision Machining ◽  
Abrasive Waterjet Machining ◽  
Abrasive Grain ◽  
Waterjet Machining

The research involves experimental study on precision machining of hybrid composite stacks using Submerged Abrasive Waterjet Machining (SAWJM) process. In this study, an in-house fabricated SAWJM setup is used to machine a stack of Carbon Fiber Reinforced Polymer (CFRP) and Titanium. The effect of critical parameters including stand-off distance and abrasive grain size on the size of the cavity machined during SAWJM and Abrasive Waterjet Machining (AWJM) processes are studied. The study found that SAWJM process is capable of successfully machining CFRP/Titanium composites with high precision. The machined surface is free of thermal stresses and did not show any delamination or cracking around the edges. The study suggested that the stand-off distance and abrasive grain size has significant influence on the machining process. The cavities machined on both CFRP and titanium during SAWJM process are smaller and more circular than that produced during AWJM process. The results of this study provide deeper insight into precision machining of hybrid composite stacks.

The Monitoring System for Stability of CNC Machining Based on cDAQ and LabVIEW

2014 ◽  
Vol 1039 ◽  
pp. 177-182
Author(s):  
Man Meng ◽  
Wen Jun Zhang ◽  
Peng Chong Wang ◽  
Denis Niedenzu ◽  
Ying Zhong Tian
Keyword(s):  
Monitoring System ◽  
Online Monitoring ◽  
Cnc Machining ◽  
Machining Process ◽  
Depth Of Cut ◽  
Feed Speed ◽  
Online Monitoring System ◽  
Main Factors ◽  
The Stability

In recent years, researching the stability of the CNC machining process is a hotpot in CNC industry. Based on cDAQ and labVIEW, online monitoring system is presented, meanwhile, both software structure and hardware structure are introduced in detail. Researches show that vibration and pressure are the main factors for the quality of the flatness. By studying the relative vibration between the spindle and the platform in the Z axis direction, as well as the shifty pressure that tool works on the flatness of the workpiece, four experiments are designed in this paper under different technological conditions including free moving, Axial Depth of cut, speed and feed speed, which verify the reliability of the online monitoring system.

Experimental Investigation of Abrasive Waterjet Machining of Titanium Graphite Laminates

2016 ◽  
Vol 10 (3) ◽  
pp. 392-400 ◽  
Author(s):  
M. Ramulu ◽  
◽  
Vara Isvilanonda ◽  
Rishi Pahuja ◽  
Mohamed Hashish ◽  
...  
Keyword(s):  
Experimental Investigation ◽  
Titanium Alloy ◽  
High Temperature ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Material System ◽  
Operating Variables

High temperature Fiber Metal Laminate – Titanium/Graphite (Ti/Gr) is an advanced material system, developed to meet the high temperature requirements in aerospace applications. High specific strength and stiffness of composite core along with its protection from aggressive environment by tough titanium alloy sheets qualify FMLs for a promising alternative material where metallic and composites overcome each other's limitations. However, industrial employability of this three phase system is often limited by the machining challenges posed by the difference in material removal mechanisms of Titanium alloy, PIXA thermoplastic polyimide resin and graphite fibers. An experimental investigation was conducted to evaluate the machinability of 1 mm thick Ti/Gr laminate sheets through Abrasive Waterjet (AWJ) machining process in terms of kerf characteristics and material removal rate. The parametric influence of AWJ operating variables on machining performance was studied by systematically measuring operating variables (traverse speed and Abrasive flow rate) using fully crossed Design of experiment (DOE) scheme, and statistically analyzing using ANOVA (Analysis of variance) technique. Empirical models were developed to quantify these effects and predict the influence of process parameters on material removal rate, kerf taper, entry damage width and overcut in straight cutting of Ti/Gr sheets.

Optimization of Multi-Responses in Hot Turning of Inconel 625 Alloy Using DEA-Taguchi Approach

2016 ◽  
Vol 24 ◽  
pp. 57-63 ◽  
Author(s):  
A.K. Parida ◽  
K.P. Maity
Keyword(s):  
Taguchi Method ◽  
Material Removal Rate ◽  
Surface Finish ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Machining Parameter ◽  
Hot Turning

In the present work DEA (data envelopment analysis) coupled with Taguchi method has used for optimization in process parameters of hot turning operation. An experimental investigation has been carried out to study the effect of cutting parameters such as speed, feed and depth of cut during. The material removal rate and surface finish, are to be studied with respect to machining at 450 temperature by heating Inconel 625. In order to achieve both quality and productivity, optimization of both is necessary simultaneously. DEA –Taguchi method can employed for solving in multi-response problem. LINGO software was used to find out the relative efficiency and converted to S/N ratio using MINITAB software. The optimization of the machining parameter found at 100 m/min cutting speed, 0.15 mm/rev feed rate and 1 mm depth of cut. Depth of cut is the most influencing parameter which affect both surface finish and material removal rate in the machining process.

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