Optimization of Kerf Surface and Material Removal Rate Using Abrasive Water-Slurry Jet Machining Setup

Abstract

This work presents a description of abrasive water-slurry jet machining (AWSJM) to improve machining capabilities of conventional abrasive water jet machine. The present work proposes a new approach of AWSJM by equipping the conventional abrasive water jet machine (AWJM) with a programmable servomotor controlled abrasive flow control valve and fabricating a setup for injecting polymer solution into the abrasive water jet nozzle, which improves the performance of abrasive jet. Three types of concentrations are prepared to perform the experiments at different values of pressure, abrasive flow rate and abrasive size. The present work identifies the optimal range of process parameters for AWSJM, with natural gelatin as binder, with the response parameters being material removal rate and kerf width. Gelatin produces a coherent, 4-phase beam which leads to efficient energy transfer, improved cutting efficiency, increased material removal rate, reduced kerf width, reduced diversification of jet and better control of abrasive flow rate. The investigation shows that materials removal rate (MRR) tends to increase for approximate 20% (by weight) concentration of polymer in AWSJM. If the polymer is mixed in lower quantities, the MRR is almost equal or less than the MRR for AWJM.