Abrasive Mass Flow Rate Research Articles

An experimental investigation into the potential of employing mixed eco-friendly abrasives during AWJ milling of nickel-based superalloy

Non-conventional machining processes are capable of achieving higher performance compared to conventional ones due to their inherent characteristics and higher amount of parameters which can be favorably regulated. Although the correlation between the most important process parameters and process outcome has been already established for a wide range of conditions and workpiece materials, the introduction of new considerations related to the three pillars of sustainability require further investigation on new means for the enhancement of AWJ milling process. As one of the most important parameters in AWJ milling is the abrasive material, the introduction of new materials may offer considerable advantages from different perspectives. Thus, in the present work, a comprehensive investigation on the efficiency of using eco-friendly, mixed abrasives is carried out under various conditions such as different traverse feed rate, abrasive mass flow rate, water jet pressure, jet impingement angle, and mixing ratio. The feasibility of using mixed abrasives is evaluated in terms of achievable depth of penetration, kerf width, kerf taper angle as well as material removal rate (MRR), and cutting efficiency. The findings indicate that among other factors, the mixing ratio plays a noticeable role especially regarding MRR and cutting efficiency and can offer an additional effective means to achieve the desired kerf characteristics in conjunction with other significant parameters such as water jet pressure.

Surface Topography Analysis of BK7 with Different Roughness Nozzles Using an Abrasive Water Jet.

This study investigated the effect of abrasive water jet (AWJ) kinematic parameters, such as jet traverse speed and water pressure, abrasive mass flow rate, and standoff distance on the surface of BK7. Nozzle A reinforced with a 100 nm particle-sized coating of titanium alloy has more wear resistance compared to Nozzle B coated with nothing. Through analysis of variance and measurement of BK7 surface quality, it is concluded that the grooving and plowing caused by abrasive particles and irregularities in the abrasive water jet machined surface with respect to traverse speed (3, 7.2, 7.8, and 9 mm/min), abrasive flow rate (7 L/min and 10 L/min, 80 mesh) and water pressure (2 and 3 MPa) were investigated using surface topography measurements. The surface roughness (15.734 nm) of BK7 results show that a nozzle coated with titanium alloy has more hardness, which protects BK7 undamaged and super-smooth. The values of selected surface roughness profile parameters-average roughness (Ra) and maximum height of PV (maximum depth of peak and valleys)-reveal a comparatively smooth BK7 surface in composites reinforced with 2% titanium alloy in the nozzle weight at a traverse speed of 7.8 mm/min. Moreover, abrasive water jet machining at high water pressure (3 MPa) produced better surface quality due to material removal and effective cleaning of lens fragmentation and abrasive particles from the polishing zone compared to a lower water pressure (2 MPa), low traverse speed (5 mm/min), and low abrasive mass flow rate (200 g/min).

Application of Abrasive Water Jet Cutting on Rubber Wood Plastic Composites

Wood-plastic composites (WPCs) possess a diverse arrange of advantageous characteristics resulting from the combination of wood and plastic. These include a prolonged lifespan, cost-effectiveness, and environmental friendliness. However, the net shape can only be roughly achieved by the extrusion method used to make WPCs. WPCs require additional machining to comply with the dimensional accuracy and assembly conditions. As a result, more research into the cutting process of this composite is needed. In this work, abrasive water jet cutting was used to cut WPCs manufactured from rubber wood flour and polypropylene (PP). The emphasis was on two distinctive architectures of 1-layered and 3-layered WPCs with a thickness of 10 mm. The effects of cutting factors including water pressure, traverse speed, and abrasive mass flow rate were taken into account. The study employed a full factorial analysis to investigate the correlation between cutting parameters and cutting performance, including kerf characteristics and machined surface roughness. The abrasive and water pressure in the experiment had a significant effect in cutting both materials. In some cutting conditions, without an abrasive, non-through cutting happens, particular for the 3-layered WPC structures, that are particularly strong. An increase in water pressure decreased machining surface roughness and kerf width. The cutting parameters of 350 MPa water pressure, 30 mm/s traverse speed, and 6.67 g/s abrasive flow rate were suggested for both the 1-layered and 3-layered WPCs structures. This procedure was considered suitable for post-cutting without requiring for surface finishing.

Experimental study of abrasive water jet drilling parameters on UHMWPE for biomedical implant applications

ABSTRACT This study addresses this issue by exploring the effectiveness of abrasive water jet drilling (AWJD) as an unconventional machining approach for UHMWPE. The research employs a full factorial analysis to examine various hole characteristics, including machining time (MT), surface roughness (Ra), taper angle (TA), material removal rate (MRR), and taper ratio (TR). The study aims to understand the effect of the process features, namely abrasive water jet pressures (p), traverse rates (v), and abrasive mass flow rates (ma), on the geometry and position of the drilled holes. The results show that (v) and (p) affect the drilled hole characteristics of surface morphology, roughness, MT, MRR, TA, and TR. The microstructural characteristics of the drilled-hole surfaces are analyzed by scanning electron microscopy (SEM). It revealed that the smooth surface is attained at the lower v of 150 mm/min and ma of 250 g/min.

Enhancing High-Alloy Steel Cutting with Abrasive Water Injection Jet (AWIJ) Technology: An Approach Using the Response Surface Methodology (RSM).

The common machining technologies for difficult-to-machine materials do not remarkably ensure acceptable efficiency and precision in bulk materials cutting. High-energy abrasive water injection jet (AWIJ) treatment can cut diverse materials, even multi-layer composites characterized by divergent properties, accurately cutting complex profiles and carrying them out in special circumstances, such as underwater locations or explosion hazard areas. This work reports research on the AWIJ machining quality performance of X22CrMoV12-1 high-alloy steel. The response surface method (RSM) was utilized in modeling. The most influencing process control parameters on cut kerf surface roughness-abrasive flow rate, pressure, and traverse speed-were tested. The result is a mathematical model of the process in the form of a three-variable polynomial. The key control parameter affecting the cut slot roughness turned out to be the traverse speed. In contrast, pressure has a less significant effect, and the abrasive mass flow rate has the slightest impact on the cut slot roughness. Under the optimal conditions determined as a result of the tests, the roughness of the intersection surface Sq does not exceed 2.3 μm. Based on the ANOVA, we confirmed that the model fits over 96% appropriately with the research outcomes. This method reduces the computations and sharply determines the optimum set of control parameters.

Monitoring Equipment Malfunctions in Composite Material Machining: Acoustic Emission-Based Approach for Abrasive Waterjet Cutting

This paper introduces an Acoustic Emission (AE)-based monitoring method designed for supervising the Abrasive Waterjet Cutting (AWJC) process, with a specific focus on the precision cutting of Carbon Fiber-Reinforced Polymer (CFRP). In industries dealing with complex CFRP components, like the aerospace, automotive, or medical sectors, preventing cutting system malfunctions is very important. This proposed monitoring method addresses issues such as reductions or interruptions in the abrasive flow rate, the clogging of the cutting head with abrasive particles, the wear of cutting system components, and drops in the water pressure. Mathematical regression models were developed to predict the root mean square of the AE signal. The signal characteristics are determined, considering key cutting parameters like the water pressure, abrasive mass flow rate, feed rate, and material thickness. Monitoring is conducted at both the cutting head and on the CFRP workpiece. The efficacy of the proposed monitoring method was validated through experimental tests, confirming its utility in maintaining precision and operational integrity in AWJC processes applied to CFRP materials. Integrating the proposed monitoring technique within the framework of digitalization and Industry 4.0/5.0 establishes the basis for advanced technologies such as Sensor Integration, Data Analytics and AI, Digital Twin Technology, Cloud and Edge Computing, MES and ERP Integration, and Human-Machine Interface. This integration enhances operational efficiency, quality control, and predictive maintenance in the AWJC process.

Experimental Analysis of Kerf Characteristics of Carbon Fiber-Reinforced Polymer with Abrasive Water Jet Machining

<div>This research looks into how abrasive water jet machining (AWJM) can be used on carbon fiber-reinforced polymer (CFRP) materials, specifically how the kerf characteristics change with respect to change in process parameters. We carefully looked into four important process parameters: stand-off distance (SOD), water pressure (WP), traverse rate (TR), and abrasive mass flow rate (AMFR). The results showed that as SOD goes up, the kerf taper angle goes up because of jet dispersion, but as WP goes up, the angle goes down because jet kinetic energy goes up. The TR was directly related to the kerf taper angle, but it made the process less stable. The kerf drop angle was not greatly changed by AMFR. When it came to kerf top width, SOD made it wider, WP made it narrower, TR made it narrower, and AMFR made it a little wider. When the settings (SOD: 1 mm, WP: 210 MPa, TR: 150 mm/min, AMFR: 200 g/min) were optimized, the kerf taper angle and kerf top width were lowered. This improved the accuracy of the measurements and cut down on material waste in CFRP composite machining. These results make it clear how important parameter selection is in precision cutting.</div>

Determination and prediction of surface and kerf properties in abrasive water jet machining of Fe-Cr-C based hardfacing wear plates

Improving and maintaining the sustainability, profitability and efficiency of sectors such as manufacturing, mining and agriculture are the most important goals for industries. It is therefore quite common to apply hardfacing method to products and equipment created to achieve these goals. However, machining of the workpiece is necessary to ensure dimensional accuracy as a result of hardfacing production. In the processing of hardfacing materials with traditional machining methods, negative factors such as tool wear and thermal effects occur. For this reason, the cutting performance of hardfacing wear plate with abrasive water jet, which is one of the unconventional manufacturing processes, was investigated in this study. Tests were realized in regard to the full factorial experimental design, which includes the changes in the levels of material alignment direction, abrasive mass flow rate and traverse speed parameters. The influences of the test parameters on the surface roughness and kerf taper angle constituting the cutting performance were determined by analysis of variance (ANOVA). In addition, the effects of changes in parameter levels were investigated. Material alignment direction was found to be the most effective test parameter for surface roughness and kerf taper angle. The influences of parameter and parameter levels on the formation of surface conditions were determined with surface images. Thus, machining mechanisms and surface morphologies were explained by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). Optimal levels of test parameters were achieved by performing multiple-response optimization with equal importance. Finally, the estimated results of cutting performances were found by general linear model, and all results were confirmed by regression analysis.

An experimental assessment and optimisation of hole quality in Al2024-T3 aluminium alloy during abrasive water jet machining

Owing to its outstanding properties such as corrosion resistance, low density, relatively low cost, and stiffness, Al2024-T3 aluminium alloy has been widely applied in aircraft manufacturing. To perfectly assemble an aircraft, numerous high-quality holes are drilled into its structures employing conventional drilling processes. Conventional drilling poses some challenges such as thermal distortions, burr formations, and tool wear. Alternatively, abrasive water jet drilling (AWJD) is a thermal-free machining process that can be employed as an alternative to conventional drilling of aeronautical structures. Hence, in this work, the effect of abrasive water jet parameters, namely stand-off distance, water jet pressure, and abrasive mass flow rate, on hole-quality parameters was evaluated at traverse speed = 10 mm/min. Three parameters were stand-off distance = 1, 2, and 3 mm, abrasive mass flow rate = 200, 250, and 300 g/min, and water jet pressure = 1800, 2100, and 2600 bar. Using a 6 mm circular-movement diameter of the nozzle tip, optimal stand-off distance, water jet pressure, and abrasive mass flow rate obtained by multi-objective optimization were 2 mm, 250 g/min, and 2600 bar, respectively. The corresponding hole-quality parameters were Diameter = 6.232 mm, Kerf angle = 0.018°, Cylindricity = 0.051 mm, Perpendicularity = 0.033 mm, Circularity = 0.0041 mm and Surface roughness Ra = 2.909 µm. The results showed that water jet pressure had the greatest influence on Perpendicularity, Circularity; stand-off distance had the highest effect on Kerf angle; and abrasive mass flow rate has the largest influence on Hole diameter, Cylindricity and Surface roughness Ra, and Rz at the given value of traverse speed. The adopted optimization process for abrasive water jet of Al2024-T3 aluminium alloy was successfully verified through confirmation runs, clearly illustrating its benefits.

Statistical modelling of depth milling in Ti-6AL4V using abrasive water jet machining

Multi-objective grey relational analysis optimization technique and multiple regression analysis were employed to determine the optimum values for depth of cut, surface roughness ( Ra), and kerf at entry and exit ([Formula: see text] and [Formula: see text]), for abrasive waterjet machining of Ti6AL4V materials. This method highlights a new process to extend the grey relational analysis technique for determining the optimum conditions for obtaining the best quality characteristics. The input parameters of the study were water pressure ( Wp), transverse speed ( Ts), abrasive mass flow rate ( Amf), abrasive orifice size ( Aos), nozzle/orifice diameter ratio ( N/Odia). The experiments were conducted as per the Taguchi-based L27 orthogonal array. The grey relational analysis technique found that Ts was the most significant parameter on the combined outputs. The regression models developed had an R2 of 81.58%, 79.79%%, 77.20%, and 74.39% for depth of cut, Ra, [Formula: see text] and [Formula: see text], respectively. Additionally, the analysis of variance showed that Wp and Aos had a significant influence on the output parameters. The predicted values were found to be reasonably close with the experimental values, and the maximum average deviation was 8.15% for [Formula: see text].

PROCESS OPTIMIZATION BY APPLYING THE RESPONSE SURFACE METHODOLOGY (RSM) TO THE ABRASIVE SUSPENSION WATER JET CUTTING OF PHENOLIC COMPOSITES

The paper introduces the study on the cutting of the industrial composite phenolic resin, based on the thermoset materials reinforced with cotton cloth by the Abrasive Water Suspension Jet (AWSJ). The size reduction of abrasive grains during the formation of the jet and the erosion phenomenon are shown. The results of the machining process's critical factors as nozzle length, nozzle diameter, and abrasive mass flow rate on the maximal cutting depth, are indicated. To build a model of the process, the method of the response surface (RSM) was applied. The second-degree multinomial equation is selected for creating the cutting model. The research indicates the optimal control factors of the process, to achieve the best cutting depth performance.

Optimization of Process Parameters to Minimize the Surface Roughness of Abrasive Water Jet Machined Jute/Epoxy Composites for Different Fiber Inclinations

Composites materials like jute/epoxy exhibit high hardness and are considered as difficult-to-machine materials. As a result, alternatives to conventional machining become essential to post-process the composites. Accordingly, due to its non-thermal nature, abrasive water jet machining has recently come to be seen as one of the most promising machining methods for composite materials. In the current study, the impact of machining parameters such as traverse speed (TS), standoff distance (SOD) and abrasive mass flow rate (MFR) on machined surface roughness (Ra) has been investigated. In addition, the optimum combination of process parameters to machine a jute fiber-reinforced polymer composite with minimum Ra is predicted. The experimental results are analyzed using Taguchi and Response Surface Methodology (RSM) approaches to determine the optimum set of process parameters to achieve the lowest roughness values. Without making any changes in the machining conditions, the optimum set of values is determined for two conditions by reinforcing the fiber with 45° inclination and 90° inclination. The results reflect the different optimum combinations for each fiber inclination. For 45° fiber inclination, to achieve the minimum Ra value, the predicted combination is TS = 30 mm/min, SOD = 2 mm and MFR = 0.35 kg/min. When the fiber inclination is 90°, the predicted optimum combination is TS = 25 mm/min, SOD = 2 mm, and MFR = 0.35 kg/min. It is evident from the results that the optimum combination will be changed according to the machining conditions as well as material properties. The results confirm the effect of fiber orientation on surface roughness. The specimen with 45° fiber inclination produces a lower Ra with an average of 4.116 µm, and the specimen with 90° fiber inclination generates a higher Ra with an average of 4.961 µm.

A Study to Investigate the Influence of Machining Parameters on Delamination in the Abrasive Waterjet Machining of Jute-Fiber-Reinforced Polymer Composites: An Integrated Taguchi and Response Surface Methodology (RSM) Optimization to Minimize Delamination

In recent years, abrasive waterjet machining has emerged as a promising machining technique for the machining of composites because of its non-thermal nature. In the present study, the effect of machining parameters on the quality of machining has been studied and the process parameters have been optimized to machine jute-fiber-reinforced polymer composites. The design of the experiment was used to predict the combination of the input parameters for L27 experiments. Taguchi and response surface methodology (RSM) techniques were employed to analyze the experimental data and identify the optimum combination of process parameters to achieve as little delamination as possible. The results indicate that an increase in the values of the parameters traverse speed and abrasive mass flow rate leads to an increase in the damage obtained. However, an increase in the value of the parameter stand-off distance minimizes the damage produced. To achieve minimum delamination, the optimum combination of input parameters is obtained through Taguchi and RSM. For the present experimental condition, to achieve minimum delamination, the parameter traverse speed should be set at 20 mm/min, the stand-off distance should be 4 mm, and the abrasive flow rate should be set at 0.25 kg/min. The results confirm that the optimum combination of parameters obtained through both approaches is similar. This investigation results indicated a significant improvement in the cutting quality with reduced damage, achieved through the optimized process parameters. For the considered range of parameters, graphs are plotted such that any intermediate values can be anticipated within the considered range without performing any further experiments. The present work signifies the effect of fiber orientation on delamination.

Determination and Application of Optimum Abrasive Mass Flow Rate of Abrasive Waterjet

Abrasive waterjet can be effectively used in cutting reinforced concrete (RC) piles. The cutting performance increases with abrasive mass flow rate, but as the abrasive mass flow rate increases, damage of abrasive particles also increases. Using optimum abrasive mass flow rate in cutting RC piles, which is determined by considering damage of abrasive particles, can improve cutting performance. In this paper, quantification of effect of abrasive waterjet parameters on cutting performance is simplified by using maximum kinetic energy as medium to relate abrasive waterjet parameters to cutting depth. The damage of abrasive particles during acceleration is related to mixing tube diameter, abrasive material properties and gradation, and is independent of pump pressure, water mass flow rate, transverse speed, standoff distance (SOD), jet impingement angle, and number of cuts. It is found that damage of abrasive particles leads to a reduction of effective kinetic energy used in cutting RC structures. The model for prediction of optimum abrasive mass flow rate is proposed by introducing coefficient of momentum transfer, which considers loss of kinetic energy during acceleration. The optimum abrasive mass flow rate calculated based on proposed model is then used in field test, which shows obvious improvement of cutting performance.

Optimization of machining parameters & studies on characteristics of Monel k400 alloy using abrasive water jet Machining using ANFIS

The Monel k400 alloy is a nickel-copper based alloy with an excellent corrosion resistance that exhibits better weldability and high strength. Also, it exhibits excellent resistance to either rapid flowing brackish water or seawater. Monel k400 alloy (UNS N04400) is widely used in oil, chemical and marine industries. Therefore, machinability of material plays a vital role in adopting material. As a result, in the current work, Monel k400 is used and manufactured utilizing an advanced machining method called an AWJM to examine the impact of process parameters on the machinability of alloy. The purpose of this study was to investigate the effects of abrasive mass flow rate, nozzle traverse speed, and stand-off distance on surface roughness. Adaptive Neuro-Fuzzy Inference System (ANFIS) model is used in order to predict surface roughness upon varying Abrasive Water Jet Machining process parameters for a lesser prediction error. In AWJM process Mean Absolute Percentage Error (MAPE) in between experimental, predicted surface roughness is found to be 3.46% which reflects efficacy of ANFIS model in predicting of surface roughness was evaluated to an extent of credibility. Also, the coefficient of determination R2 is evaluated and found to be 0.943, which indicates a good fit for prediction using the model against measured surface roughness values.

Process parameters optimization in machining of monel 400 alloy using abrasive water jet machining

This research examines the optimum machining features for abrasive water jet cutting of Monel 400 alloy. This alloy system faces significant challenges in conventional machining and can be surpassed by using the coolest machining technology, such as AWJM. In this experimental investigation, the water beam jet pressure (AP), the nozzle jet traverse speed (NS), and the abrasive flow rate (AMF) were used to explore the kerf taper angle (Kta) and surface roughness (Ra) response variables. The experimental L-9 layout (Taguchi's/L-9(−|-) standard orthogonal array) was used to run the experiment. The S/N ratios for each experimental run were determined using a mono-output response optimization technique. The input characteristics, such as water beam jet pressure (AP) and abrasive flow rate (AMF), were determined to have the most substantial effects on kerf taper angle (Kta) and surface roughness (Ra). While increased water pressure (AP) caused a narrowed jet, reducing the kerf taper angle (Kta) and surface roughness (Ra). Its simultaneous abrasive mass flow rate (AMF) increase causes constant erosion on the cutting front, resulting in a smooth surface roughness (Ra) and less kerf taper angle (Kta). Confirmation tests were carried out using the optimal input parameter combinations found by the statistical program to establish effective solutions to the machining.

Optimization of Abrasive Water Jet Machining Process Parameters on Onyx Composite Followed by Additive Manufacturing

Fiber-reinforced additive manufacturing components have been used in various industrial applications in recent years, including in the production of aerospace, automobile, and biomedical components. Compared to conventional methods, additive manufacturing (AM) methods can be used to obtainin lighter parts with superior mechanical properties with lower setup costs and the ability to design more complex parts. Additionally, the fabrication of onyx composites using the conventional method can result in delamination, which is a significant issue during composite machining. To address these shortcomings, the fabrication of onyx composites via additive manufacturing with the Mark forged 3D-composite printer was considered. Machinability tests were conducted using abrasive water jet machining (AWJM) with various drilling diameters, traverse speeds, and abrasive mass flow rates. These parameters were optimized using Taguchi analysis and then validated using the Genetic algorithm (GA) and the Moth Flame Optimization algorithm (MFO). The surface morphology (Dmax) and the roughness of the drilled holes were determined using a vision measuring machine with 2D software (MITUTOYO v5.0) and a contact-type surface roughness tester. Confirmation testing demonstrated that the predicted values werenearly identical to the experimental standards. During the drilling of an onyx polymer composite, regression models, genetic algorithms and the Moth-Flame Optimization algorithm were used to estimate the response surface of delamination damage and surface roughness.

Simulation analysis and evaluation of decontamination effect of different abrasive jet process parameters on radioactively contaminated metal

A new method of numerical simulating prediction and decontamination effect evaluation for abrasive jet decontamination to radioactively contaminated metal is proposed. Based on the Computational Fluid Dynamics and Discrete Element Model (CFD-DEM) coupled simulation model, the motion patterns and distribution of abrasives can be predicted, and the decontamination effect can be evaluated by image processing and recognition technology. The impact of three key parameters (impact distance, inlet pressure, abrasive mass flow rate) on the decontamination effect is revealed. Moreover, here are experiments of reliability verification to decontamination effect and numerical simulation methods that has been conducted. The results show that: 60Co and other homogeneous solid solution radioactive pollutants can be removed by abrasive jet, and the average removal rate of Co exceeds 80%. It is reliable for the proposed numerical simulation and evaluation method because of the well goodness of fit between predicted value and actual values: The predicted values and actual values of the abrasive distribution diameter are Ф57 and Ф55; the total coverage rate is 26.42% and 23.50%; the average impact velocity is 81.73 m/s and 78.00 m/s. Further analysis shows that the impact distance has a significant impact on the distribution of abrasive particles on the target surface, the coverage rate of the core area increases at first, and then decreases with the increase of the impact distance of the nozzle, which reach a maximum of 14.44% at 300 mm. It is recommended to set the impact distance around 300 mm, because at this time the core area coverage of the abrasive is the largest and the impact velocity is stable at the highest speed of 81.94 m/s. The impact of the nozzle inlet pressure on the decontamination effect mainly affects the impact kinetic energy of the abrasive and has little impact on the distribution. The greater the inlet pressure, the greater the impact kinetic energy, and the stronger the decontamination ability of the abrasive. But in return, the energy consumption is higher, too. For the decontamination of radioactively contaminated metals, it is recommended to set the inlet pressure of the nozzle at around 0.6 MPa. Because most of the Co elements can be removed under this pressure. Increasing the mass and flow of abrasives appropriately can enhance the decontamination effectiveness. The total mass of abrasives per unit decontamination area is suggested to be 50 g because the core area coverage rate of the abrasive is relatively large under this condition; and the nozzle wear extent is acceptable.

Minimization of surface roughness and residual stress in abrasive water jet cutting of titanium alloy Ti6Al4V

Concrete, ceramics, rocks, metal-matrix composites, titanium alloys and other hard-to-cut materials are frequently cut using the non-traditional cold processing method known as abrasive water jet machining (AWJM). A virtual machining system is proposed in the study to minimize roughness of surface and residual stress during AWJM of titanium alloy Ti6Al4V. The water and workpiece are simulated in virtual environments using the smoothed particle hydrodynamics (SPH) approach and finite element method, respectively. Then, the Johnson–Cook law model of titanium alloy is used to obtain the cutting temperature during cutting operations. To calculate residual stress during the AWJM operations, the finite element method is then utilized. The Taguchi optimization method is implemented to minimize surface roughness and residual stress in AWJM operations. Thus, the optimized machining parameters such as water jet pressure, traverse speed, abrasive mass flow rate and standoff distance are calculated to minimize the surface roughness and residual stress during the AWJM of titanium alloy Ti6Al4V. Experimental and computational examinations are carried out in order to validate the effectiveness and efficiency of proposed virtual machining system in minimization of surface roughness and residual stress during abrasive waterjet cutting of titanium alloy Ti6Al4V. As a result, by using the optimized machining parameters, 23.7% and 27.1% reduction in the measured and predicted residual stress of sample machined part are obtained. Also, the sample machined part’s surface roughness is reduced by 26.7% and 27.9%, for the measured and predicted surface roughness of sample machined part, respectively. So, the quality and reliability of the machined parts can be enhanced using the developed virtual machining system in the study to minimize the surface roughness and residual stress in AWJM operations.

Influence of process parameters on delamination of GFRP with abrasive water jet machining

Abrasive water jet machining (AWJM) is extensively employed for machining composites such as glass fibre-reinforced polymers (GFRP). AWJM has been demonstrated to be a cost-effective and practical material removal technique for composites, in which a high-speed jet of abrasive and water erodes the material on the workpiece surface. In this paper, an experimental investigation is explained which is focused on investigating the impact of process parameters on the delamination of machined samples during AWJM of GFRP composites. Four main process parameters namely water pressure (WP), traverse rate (TR), standoff distance (SOD), and abrasive mass flow rate (AMFR) are considered to study their influence on delamination. For design of experiments Minitab 18′s Taguchi L16 orthogonal array is used, and ANOVA is applied to find out the significance and effect of process parameters on delamination. It is revealed that delamination increases with an increase in traverse rate and water pressure and is prominent at the bottom portion of machined samples. The delamination is measured using a scanning electron microscope (SEM).