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.

scholarly journals Impacts of traverse speed and material thickness in abrasive waterjet contour cutting of Austenitic stainless steel AISI 304L

2021 ◽  
Author(s):  
Jennifer llanto ◽  
Majid Tolouei-Rad ◽  
Ana Vafadar ◽  
Muhammad Aamir
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Taper Angle ◽  
Material Thickness ◽  
Kerf Taper

Abstract Austenitic stainless steel 304L (AISI304L), of varied thickness, is widely used in the fabrication industry and in many cases, it requires contour machining for achieving intricate profiles. Abrasive water jet machine is a proficient alternative for machining difficult-to-cut, reflective, conductive, and heat-sensitive materials such as austenitic stainless steel with complex geometries. However, due to differences in machining responses for varied material conditions, the abrasive waterjet machine experiences challenges such as kerf geometric inaccuracy and low material removal rate. In this study, an abrasive waterjet machine is employed to perform contour cutting of different profiles to investigate the impacts of traverse speed and material thickness in achieving a lower kerf taper angle and higher material removal rate. Experimental results show that all profiles encountered a similar trend of obtaining higher kerf taper angle and material removal rate as traverse speed increased. Analysis of variance revealed that material thickness denotes a more significant impact to kerf taper angle and material removal rate with a contribution within the range of 69%-91% and 62-69% respectively; whereas traverse speed indicates the least contributing factor within the range of 5%-18% in kerf taper angle and 27%-36% for material removal rate.

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.

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.

MULTI-RESPONSE OPTIMIZATION ON ABRASIVE WATERJET MACHINING OF GLASS FIBER REINFORCED PLASTICS USING TAGUCHI METHOD COUPLED WITH TOPSIS

2021 ◽  
Author(s):  
A. SHANMUGAM ◽  
T. MOHANRAJ ◽  
K. KRISHNAMURTHY ◽  
ALI KAYA GUR
Keyword(s):  
Glass Fiber ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Taper Angle ◽  
Reinforced Plastics ◽  
Abrasive Waterjet Machining ◽  
Glass Fiber Reinforced ◽  
Waterjet Machining ◽  
Response Optimization ◽  
Fiber Reinforced Plastics

This work aims to perform the multi-response optimization for abrasive waterjet machining (AWJM) of glass fiber reinforced plastics (GFRP). The experiments were conducted with AWJM factors like pressure (P), traverse speed (TS), and standoff distance (SOD) at three levels. Taguchi’s L9 orthogonal array (OA) was used to design the experiments. The influence of control factors was evaluated by measuring the surface roughness and taper angle while cutting GFRP. The optimum parameter for an individual response was obtained through Taguchi’s [Formula: see text]/[Formula: see text] and multi-response optimization was performed with TOPSIS. From TOPSIS, the optimal parameter of the pressure of 200 MPa, standoff distance (SOD) of 1.5[Formula: see text]mm, and traverse speed (TS) of 25[Formula: see text]mm/min were found. After optimization, the taper angle was decreased by 1.41%. The influence of cutting variables on the responses was statistically analyzed through analysis of variance. It was observed that the pressure has a significant effect on multi-response characteristics and a contribution of 85.90%. After, AWJM, the surface was examined using SEM analysis and found the deformation and pull-out of fibers.

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.

scholarly journals Investigation of the Effects of Machining Parameters on Material Removal Rate in Abrasive Waterjet Turning

2014 ◽  
Vol 6 ◽  
pp. 624203 ◽  
Author(s):  
Iman Zohourkari ◽  
Mehdi Zohoor ◽  
Massimiliano Annoni
Keyword(s):  
Flow Rate ◽  
Material Removal Rate ◽  
Rotational Speed ◽  
Material Removal ◽  
Removal Rate ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Cutting Head

The effects of the main operational machining parameters on the material removal rate (MRR) in abrasive waterjet turning (AWJT) are presented in this paper using a statistical approach. The five most common machining parameters such as water pressure, abrasive mass flow rate, cutting head traverse speed, workpiece rotational speed, and depth of cut have been put into a five-level central composite rotatable experimental design (CCRD). The main effects of parameters and the interaction among them were analyzed by means of the analysis of variance (ANOVA) and the response surfaces for MRR were obtained fitting a second-order polynomial function. It has been found that depth of cut and cutting head traverse speed are the most influential parameters, whereas the rotational speed is insignificant. In addition, the investigations show that interactions between traverse speed and pressure, abrasive mass flow rate and depth of cut, and pressure and depth of cut are significant on MRR. This result advances the AWJT state of the art. A complete model discussion has been reported drawing interesting considerations on the AWJT process characterising phenomena, where parameters interactions play a fundamental role.

scholarly journals Analysis and Optimization of Process Parameters in Abrasive Waterjet Contour Cutting of AISI 304L

Metals ◽  
2021 ◽  
Vol 11 (9) ◽  
pp. 1362
Author(s):  
Jennifer Milaor Llanto ◽  
Ana Vafadar ◽  
Muhammad Aamir ◽  
Majid Tolouei-Rad
Keyword(s):  
Surface Roughness ◽  
Mass Flow Rate ◽  
Mass Flow ◽  
Process Parameters ◽  
Flow Rate ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Traverse Speed ◽  
Abrasive Waterjet

Abrasive waterjet machining is applied in various industries for contour cutting of heat-sensitive and difficult-to-cut materials like austenitic stainless steel 304L, with the goal of ensuring high surface integrity and efficiency. In alignment with this manufacturing aspiration, experimental analysis and optimization were carried out on abrasive waterjet machining of austenitic stainless steel 304L with the objectives of minimizing surface roughness and maximizing material removal rate. In this machining process, process parameters are critical factors influencing contour cutting performance. Accordingly, Taguchi’s S/N ratio method has been used in this study for the optimization of process parameters. Further in this work, the impacts of input parameters are investigated, including waterjet pressure, abrasive mass flow rate, traverse speed and material thickness on material removal rate and surface roughness. The study reveals that an increasing level of waterjet pressure and abrasive mass flow rate achieved better surface integrity and higher material removal values. The average S/N ratio results indicate an optimum value of waterjet pressure at 300 MPa and abrasive mass flow rate of 500 g/min achieved minimum surface roughness and maximum material removal rate. It was also found that an optimized value of a traverse speed at 90 mm/min generates the lowest surface roughness and 150 mm/min produces the highest rate of material removed. Moreover, analysis of variance in the study showed that material thickness was the most influencing parameter on surface roughness and material removal rate, with a percentage contribution ranging 90.72–97.74% and 65.55–78.17%, respectively.

Numerical and Experimental Characterization of Kerf Formation in Abrasive Waterjet Machining

2018 ◽  
Author(s):  
Joseck Nyaporo Nyaboro ◽  
Mahmoud A. Ahmed ◽  
Hassan El-Hofy ◽  
Mohamed El-Hofy
Keyword(s):  
Dynamic Characteristics ◽  
Material Removal ◽  
Removal Rate ◽  
Abrasive Particle ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Material Surface ◽  
Abrasive Waterjet Machining ◽  
Waterjet Machining ◽  
Jet Characteristics

Machining of hard-to-cut materials to a high degree of accuracy and surface quality is one of the most critical operations when fabricating different state-of-the-art engineered components. Abrasive waterjet machining (AWJM) is one of the non-conventional technologies, which is increasingly gaining a reputation for machining hard-to-cut materials. Despite many phenomenological investigations, the dynamic characteristics of the abrasive waterjet and physical interactions with the machined surface have not been thoroughly investigated in the context of understanding the machining process. The kerf geometry has been associated with several abrasive waterjet input parameters, but its characteristics have remained speculative among many researchers. In the present study, the governing equations of two-phase abrasive waterjet flow and the interaction with the material surface are developed and numerically simulated. With the help of precisely developed user-defined functions (UDF), the material removal process has been investigated. The dynamic jet characteristics and erosion rate are correlated to help characterize the kerf geometry. The proposed modelling approach is within the acceptable level of accuracy (< 5 %) when compared to experimental data. The results show that the jet dynamic characteristics and abrasive particle size significantly affect the kerf geometry and the material removal rate. The present findings not only provide a technical understanding of the AWJM process but also provide requisite guidelines in achieving high-precision machining of hard-to-cut materials.

Multiresponse Analysis in Abrasive Waterjet Machining Process on AA 6351

2014 ◽  
Vol 4 (4) ◽  
pp. 38-48 ◽  
Author(s):  
Naresh Babu Munuswamy ◽  
M. Nambi Krishnan
Keyword(s):  
Surface Roughness ◽  
Optimal Parameter ◽  
Water Pressure ◽  
Traverse Speed ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Abrasive Waterjet Machining ◽  
Waterjet Machining ◽  
Kerf Angle ◽  
Grey Relational

This study investigates optimal parameter setting in abrasive waterjet machining (AWJM) on aluminium alloy AA 6351, using taguchi based Grey Relational Analysis (GRA) is been reported. The water pressure, traverse speed and stand-off-distance were chosen as the process parameters in this study. An L9 orthogonal matrix array is used for the experimental plan. The performance characteristics which include surface roughness (Ra) and kerf angle (KA) are considered. The results indicate that surface roughness and kerf angle decreases, with increase in water pressure and decrease in traverse speed. Analysis of variance (ANOVA) illustrates that traverse speed is the major parameter (89.7%) for reducing surface roughness and kerf angle, followed by water pressure (5.85%) and standoff distance (2%) respectively. The confirmation results reveal that surface roughness reduced by 16% and kerf angle reduced by 47%. Furthermore, the surfaces were examined under scanning electron microscope (SEM) and atomic force microscope (AFM) for a detailed study

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