Optimization Factors in Abrasive-Waterjet Machining

1991 ◽  
Vol 113 (1) ◽  
pp. 29-37 ◽  
Author(s):  
M. Hashish
Keyword(s):  
High Pressure ◽  
Material Removal ◽  
Functional Performance ◽  
Abrasive Waterjet ◽  
Operational Parameters ◽  
Machining Processes ◽  
Abrasive Waterjet Machining ◽  
Sample Data ◽  
System Components ◽  
Waterjet Machining

This paper discusses the factors that need to be considered when selecting the operational parameters for abrasive-waterjet (AWJ) machining. Machining applications such as cutting, milling, and turning are considered along with sample data. The effects of different AWJ parameters on both the functional performance of the AWJ system components and the material removal process are discussed. Factors for optimizing these parameters include hardware limitations, high-pressure-related phenomena, and the performance interaction among the different nozzle components. Due to the large number of parameters and factors involved in AWJ machining processes, significant improvements in performance may be obtained by optimizing these parameters.

scholarly journals Impacts of Traverse Speed and Material Thickness on Abrasive Waterjet Contour Cutting of Austenitic Stainless Steel AISI 304L

2021 ◽  
Vol 11 (11) ◽  
pp. 4925
Author(s):  
Jennifer Milaor Llanto ◽  
Majid Tolouei-Rad ◽  
Ana Vafadar ◽  
Muhammad Aamir
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Taper Angle ◽  
Material Thickness ◽  
Abrasive Waterjet Machining ◽  
Kerf Taper ◽  
Waterjet Machining

Abrasive water jet machining is a proficient alternative for cutting difficult-to-machine materials with complex geometries, such as austenitic stainless steel 304L (AISI304L). However, due to differences in machining responses for varied material conditions, the abrasive waterjet machining experiences challenges including kerf geometric inaccuracy and low material removal rate. In this study, an abrasive waterjet machining is employed to perform contour cutting of different profiles to investigate the impacts of traverse speed and material thickness in achieving lower kerf taper angle and higher material removal rate. Based on experimental investigation, a trend of decreasing the level of traverse speed and material thickness that results in minimum kerf taper angle values of 0.825° for machining curvature profile and 0.916° for line profiles has been observed. In addition, higher traverse speed and material thickness achieved higher material removal rate in cutting different curvature radii and lengths in line profiles with obtained values of 769.50 mm3/min and 751.5 mm3/min, accordingly. The analysis of variance revealed that material thickness had a significant impact on kerf taper angle and material removal rate, contributing within the range of 69–91% and 62–69%, respectively. In contrast, traverse speed was the least factor measuring within the range of 5–18% for kerf taper angle and 27–36% for material removal rate.

Abrasive waterjet machining of Ti/CFRP/Ti laminate and multi-objective optimization of the process parameters using response surface methodology

2019 ◽  
Vol 54 (13) ◽  
pp. 1741-1759 ◽  
Author(s):  
Dhiraj Kumar ◽  
Suhasini Gururaja
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Abrasive Waterjet ◽  
Metal Composite ◽  
Damage Factor ◽  
Interface Damage ◽  
Abrasive Waterjet Machining ◽  
Composite Interface ◽  
Waterjet Machining

In present work, abrasive waterjet machining has been used to machine adhesively bonded titanium-carbon fiber-reinforced plastics-titanium hybrid laminate with varying traverse speed, jet pressure, and stand-off distance. The effect of varying abrasive waterjet machining parameters on cut quality has been quantified by material removal rate, metal composite interface damage factor, taper ratio ( T r), and surface roughness (Ra). Response surface methodology along with central composite design has been used to analyze the influence of process parameters on output responses. Additionally, analysis of variance was performed to identify the significant parameters on the output responses. For better abrasive waterjet cut quality, the optimal values of process parameters obtained were 200 MPa jet pressure, 237.693 mm/min traverse speed, and 1 mm stand-off distance. The corresponding material removal rate, metal composite interface damage factor, taper ratio, and surface roughness are 5.388 mm3/s, 1.41, 1.16, and 3.827 µm, respectively. Furthermore, validation tests have been performed with obtained optimal parameters that deliver satisfactory outcomes with an error of 5.35%, 3.07%, 2.29%, and 0.39% for material removal rate, metal composite interface damage factor, taper ratio, and surface roughness, respectively.

EXPERIMENTAL INVESTIGATION ON ABRASIVE WATERJET MACHINING OF FIBRE VINYL ESTER COMPOSITE

2019 ◽  
Vol 14 (3) ◽  
Author(s):  
Puneet Kumar ◽  
Bhavik Tank ◽  
Ravi Kant
Keyword(s):  
Surface Roughness ◽  
Vinyl Ester ◽  
Water Pressure ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Machining Processes ◽  
Significant Parameter ◽  
Abrasive Water Jet Machining ◽  
Abrasive Waterjet Machining ◽  
Waterjet Machining

Abrasive water jet machining (AWJM) is one of the most developed non-traditional machining processes. It is generally used to cut difficult to cut materials like composites. The present study is focused on machining of carbon fiber vinyl ester composite with AWJM. The effect of process parameters namely water pressure, standoff distance and traverse speed on surface roughness and kerf tapper is studied. Design of experiment is done by using Taguchi L16 orthogonal array. It is observed that water pressure is the most significant parameter followed by traverse speed. It is found that with the increase in water pressure and decrease in traverse speed of AWJM, surface roughness and kerf tapper of machined samples decreases.

Modeling Material Removal in Fracture Erosion for Brittle Materials by Abrasive Waterjet

2009 ◽  
Vol 76-78 ◽  
pp. 357-362 ◽  
Author(s):  
Hong Tao Zhu ◽  
Chuan Zhen Huang ◽  
Jun Wang ◽  
Guo Qun Zhao ◽  
Quan Lai Li
Keyword(s):  
Brittle Material ◽  
Material Removal ◽  
Brittle Materials ◽  
Abrasive Waterjet ◽  
Abrasive Waterjet Machining ◽  
Waterjet Machining ◽  
Modeling Material ◽  
Ceramic Glass ◽  
Material Removal Model ◽  
Removal Model

The abrasive waterjet machining is a powerful tool in processing various materials, especially, for brittle materials, such as ceramic, glass and so on. However, the material removal of a brittle material when impacted by abrasive waterjet is not understood in detail. In this paper, the material removal model in fracture erosion of brittle materials by abrasive waterjet has been developed.

scholarly journals Experimental Investigations into Abrasive Waterjet Machining of Carbon Fiber Reinforced Plastic

2015 ◽  
Vol 2015 ◽  
pp. 1-9 ◽  
Author(s):  
Prasad D. Unde ◽  
M. D. Gayakwad ◽  
N. G. Patil ◽  
R. S. Pawade ◽  
D. G. Thakur ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Fiber Orientation ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Experimental Investigations ◽  
Abrasive Waterjet Machining ◽  
Kerf Taper ◽  
Waterjet Machining

Abrasive waterjet machining (AWJM) is an emerging machining process in which the material removal takes place due to abrasion. A stream of abrasive particles mixed with filtered water is subjected to the work surface with high velocity. The present study is focused on the experimental research and evaluation of the abrasive waterjet machining process in order to evaluate the technological factors affecting the machining quality of CFRP laminate using response surface methodology. The standoff distance, feed rate, and jet pressure were found to affect kerf taper, delamination, material removal rate, and surface roughness. The material related parameter, orientation of fiber, has been also found to affect the machining performance. The kerf taper was found to be 0.029 for 45° fiber orientation whereas it was 0.036 and 0.038 for 60° and 90°, respectively. The material removal rate is 18.95 mm3/sec for 45° fiber orientation compared to 18.26 mm3/sec for 60° and 17.4 mm3/sec for 90° fiber orientation. The Ra value for 45° fiber orientation is 4.911 µm and for 60° and 90° fiber orientation it is 4.927 µm and 4.974 µm, respectively. Delamination factor is found to be more for 45° fiber orientation, that is, 2.238, but for 60° and 90° it is 2.029 and 2.196, respectively.

State of the Art of Research and Development in Abrasive Waterjet Machining

1997 ◽  
Vol 119 (4B) ◽  
pp. 776-785 ◽  
Author(s):  
R. Kovacevic ◽  
M. Hashish ◽  
R. Mohan ◽  
M. Ramulu ◽  
T. J. Kim ◽  
...  
Keyword(s):  
Research And Development ◽  
Material Removal ◽  
Removal Rate ◽  
The United States ◽  
High Energy ◽  
Abrasive Waterjet ◽  
Energy Beam ◽  
Abrasive Waterjet Machining ◽  
Short Period ◽  
Waterjet Machining

Thermodynamic analysis of material removal mechanisms indicates that an ideal tool for shaping of materials is a high energy beam, having infinitely small cross-section, precisely controlled depth, and direction of penetration, and does not cause any detrimental effects on the generated surface. The production of the beam should be relatively inexpensive and environmentally sound while the material removal rate should be reasonably high for the process to be viable. A narrow stream of high energy water mixed with abrasive particles comes close to meeting these requirements because abrasive waterjet machining has become one of the leading manufacturing technologies in a relatively short period of time. This paper gives an overview of the basic research and development activities in the area of abrasive waterjet machining in the 1990s in the United States.

The Development of Micro Abrasive Waterjet Machining Technology

2011 ◽  
Vol 188 ◽  
pp. 733-738 ◽  
Author(s):  
Wu Sheng Luo ◽  
Cheng Yong Wang ◽  
Jun Wang ◽  
Y.X. Song
Keyword(s):  
Solid Particle ◽  
Material Removal ◽  
Surface Cleaning ◽  
Abrasive Waterjet ◽  
Ductile Material ◽  
Particle Impact ◽  
Transportation Equipment ◽  
Abrasive Waterjet Machining ◽  
Waterjet Machining ◽  
Material Erosion

Erosion caused by solid particle impact is a very common phenomenon. In many fields such as particle (or slurry) transportation, equipment protection in a dust environment, turbine engineering, etc., prevention of particle erosion is the task. In other applications, it is used as a tool for desirable material removal, surface cleaning, controlled destruction, numerous studies on this subject have been conducted by researchers from many disciplines including physics, material science, mechanics, manufacturing, standardization, etc.. To provide a comprehensive view of the problem of erosion by solid particle impact, a review is conducted based on the literature collected on material subject of erosion by solid particle impact. The reviewed works are limited to ductile material erosion and four categories: erosion mechanism, parametric studies, material removal modeling and simulation modeling.

A Study of Kerf Characteristics in Abrasive Waterjet Machining of Graphite/Epoxy Composite

1996 ◽  
Vol 118 (2) ◽  
pp. 256-265 ◽  
Author(s):  
D. Arola ◽  
M. Ramulu
Keyword(s):  
Material Removal ◽  
Epoxy Composite ◽  
Cutting Parameters ◽  
Operating Conditions ◽  
Abrasive Waterjet ◽  
Abrasive Waterjet Machining ◽  
Initial Damage ◽  
Geometrical Features ◽  
Waterjet Machining ◽  
Laminate Thickness

Kerf geometry, kerf wall features, and cutting front characteristics of an Abrasive Waterjet (AWJ) machined Graphite/Epoxy (Gr/Ep) laminate were studied. A macroscopic analyses suggests that geometrical features associated with AWJ machining of Gr/Ep laminates are influenced by three macro regions along the cutting depth. The presence of these regions, including initial damage at jet entry, smooth cutting, and rough cutting near the jet exit, depends on the operating conditions. Design of experiments and analysis of variance were used to determine the effect of cutting parameters on kerf characteristics and to develop empirical models for kerf profile and features of the three distinct macroscopic regions. Cutting front analysis revealed that the mechanisms of material removal in AWJ machining of Gr/Ep do not change over the jet penetration depth. In general, high quality uniform cuts may be obtained by minimizing initial damage at the jet entry and by extending the smooth cutting region beyond the laminate thickness through the appropriate choice of cutting parameters.

scholarly journals Defect Analysis and Detection of Cutting Regions in CFRP Machining Using AWJM

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4055 ◽  
Author(s):  
Pedro F. Mayuet Ares ◽  
Franck Girot Mata ◽  
Moisés Batista Ponce ◽  
Jorge Salguero Gómez
Keyword(s):  
Statistical Significance ◽  
Machining Process ◽  
Alternative Methods ◽  
Abrasive Waterjet ◽  
Machining Processes ◽  
Taper Angle ◽  
Abrasive Waterjet Machining ◽  
Industrial Sectors ◽  
Waterjet Machining ◽  
High Production

The use of composite materials with a polymeric matrix, concretely carbon fiber reinforced polymer, is undergoing further development owing to the maturity reached by the forming processes and their excellent relationship in terms of specific properties. This means that they can be implemented more easily in different industrial sectors at a lower cost. However, when the components manufactured demand high dimensional and geometric requirements, they must be subjected to machining processes that cause damage to the material. As a result, alternative methods to conventional machining are increasingly being proposed. In this article, the abrasive waterjet machining process is proposed because of its advantages in terms of high production rates, absence of thermal damage and respect for the environment. In this way, it was possible to select parameters (stand-off distance, traverse feed rate, and abrasive mass flow rate) that minimize the characteristic defects of the process such as taper angle or the identification of different surface quality regions in order to eliminate striations caused by jet deviation. For this purpose, taper angle and roughness evaluations were carried out in three different zones: initial or jet inlet, intermediate, and final or jet outlet. In this way, it was possible to characterize different cutting regions with scanning electronic microscopy (SEM) and to distinguish the statistical significance of the parameters and their effects on the cut through an analysis of variance (ANOVA). This analysis has made it possible to distinguish the optimal parameters for the process.

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