Influence of Process Parameters on the Dimensions of the Channels Prepared Using Abrasive Water Jet Machining

Abstract

Preparation of micro/macro channels using unconventional machining methods/processes on hard to machine materials is increasingly in demand in the micro machining industry. AWJM is one such process that can be used for the creation of these channels. Achieving the dimensional accuracy is a challenge because process is influenced by large set of process parameters and further in depth milling process, it is much more challenging than anticipated unlike in conventional machining process. The current research is an attempt to create a channel with varying operating parameters (abrasive size, flow rate, standoff distance and traverse speed) and address the issues of 3D shape generation which is nothing but an overlap of channels for a specific freeform surface. The paper presents the variations in the dimensions of the channel with process parameters. Traverse speed decides the exposure time of the material to the jet and also the erosion capabilities. The experimental results reveal that the channel dimensions are dependent on the standoff distance which leads to the abrasive particle velocity distributions. Results obtained reveals that depth of cut is mainly dependent on the traverse speed followed by particle size. The width of the cut is dependent on the jet diameter which changes with standoff distance. The taper cut is mainly because of the particle distribution which is governed by the abrasive size and the abrasive flow rate. Proceeding in this way, we can understand the influence of process parameters on the dimensional characteristics and further to establish a base for creating complex shapes using AWJM.