Abstract
This paper investigates the effect of change of the abrasive flow rate and the jet feed on the effectiveness of machining of AZ91D casting magnesium alloy. The evaluation of the state of the workpiece surface was based on surface and area roughness parameters (2D and 3D), which provided data on: irregularities formed on the workpiece edge surface (water jet exit), the surface quality after cutting, the workpiece surface chamfering, microhardness of the machined surface, and of specimen cross-sections (along the water jet impact). The process was tested for two parameter settings: abrasive flow rate 50 at cutting speed vf = 5–140 mm/min, and abrasive flow rate 100% (0.5 kg/min) at vf = 5–180 mm/min. The results demonstrate a significant effect of the abrasive flow rate and the jet feed velocity on the quality of machined surface (surface roughness and irregularities). In addition, selected 2D surface roughness parameters were modelled using artificial neural networks (radial basis function and multi-layered perceptron). It has been shown that neural networks are a suitable tool for prediction of surface roughness parameters in abrasive water jet machining (AWJM).
Highlights
Abrasive water jet machining (AWJM) is one of the fastest developing technological methods for cutting materials
The abrasive water jet machining (AWJM) process does not affect the state of the workpiece material due to the lack of the heat affected zone, which ensures the integrity of alloy structure
The results demonstrate that the surface roughness parameter Sa increases as a function of the applied jet feed velocity
Summary
Abrasive water jet machining (AWJM) is one of the fastest developing technological methods for cutting materials. It is used, inter alia, for effective machining of aluminium alloys and “difficult-to-machine” materials such as titanium alloys or various types of composite materials. The AWJM process has the potential to become one of the most effective, unconventional subtractive machining methods (lower mechanical and thermal damage of the machined surface). It is necessary to study the influence of adjustable input parameters of the process, such as the water pump pressure, the material removal rate, the jet flow velocity, and the nozzle-workpiece distance, on the output quality and accuracy parameters
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