Module-3: ADVANCED MATERIAL REMOVAL PROCESSES

Lecture No-6 Theory, Advantages and Applications of Water Jet and Abrasive Jet Machining The theory of water jet and abrasive jet machining can be described as follows: 1. Water is forced at a sufficiently high pressure, 180-420 MPa through a small orifice in a nozzle (generally of 0.2- 0.4 mm diameter), causing high acceleration of water. 2. The potential energy of water gets further converted into kinetic energy which yields a very high jet velocity of around 1000 m/s. 3. The steam impact and high pressure of the accelerating water particles develop fine cracks on the material. 4. These fine cracks propagate further under the impact of high pressure and abrasives to the extent that the material gets cut. 5. The extended version of WJM is AWJM. In AWJM process the particles of abrasives such as sand (SiO2) or beads of glass are added in the water jet in-order to enhance its ability of cutting by many folds. 6. The AWJM are mainly of two types entrained and suspended type. In the entrained type of AWJM, the particles are allowed to draw in the water jet thereby forming an enhanced abrasive water jet with significantly higher velocities of around 800 m/s. Almost any material can be machined at such a high velocity of the abrasive jet. Advantages of WJM and AWJM In cases where the excessive heat generated can cause changes in the material properties, AWJM and WJM are very useful processes for hard metals like cutting tool steels. The water jet cutting process does not produce any dust or such particles which are harmful if inhaled like in the case of machining and grinding operations. No further secondary or finishing operations are required in most cases.

In AWJM process, the cutting forces generated on work pieces are typically low. The tooling requirements are limited Typical surface finish achieved is in the range of 125-250 microns Ra. The material wastages are reduced due to smaller kerf sizes. There is no heat affected zone. There is no cutter induced metallic contamination Eliminates thermal distortion There is no tool re-sharpening cost It can cut metals, plastics, stones, composites, glass, ceramics and rubber

Disadvantages of WJM and AWJM Cannot cut materials which degrades quickly with moisture Higher cutting speeds are frequently used for rough cutting purposes which degrade the surface finish. There is a strong possibility of cracking in brittle materials and only few varieties of materials could be cut economically. With WJM process, thick parts cannot be cut accurately and economically. In thicker materials the taper generated is also a problem. The equipment used are quite expensive There are safely concerns due to noise and high pressures

Applications of WJM and AWJM The Water Jet Cutting (WJC) process is mainly made used in cutting low strength materials like plastics, wood and aluminium. With the addition of abrasives, the AWJM process can be used for stronger materials like tool steels. Equipment The major components of Jet equipment (WJ or AWJ) are: Pump Nozzle Orifice

Control System

A pump is used to create pressure in the liquid in the range of 1500-4000 bars. In achieving this purpose, an electric motor of 50-100 HP rating is used. Nozzles are used to convert the high pressure liquid to a high velocity jet. As there is a possibility of erosion in the orifice of the nozzle due to the high pressure of liquid in WJM and that of abrasives in AWJM, a high wear resistant material is used for nozzles. Control system in the equipment helps in optimum settings for various parameters. Process Parameters The process parameters of WJM and AWJM have been grouped in the categories as shown in the Ishikawa cause and effect diagram (Fig.3.6.1). This depicts the effect of various parameters affecting the accuracy and quality of the machining operations by water jet and abrasive water jet machines. 1. Hydraulic parameters: Size of the orifice and required pressures. 2. Abrasive Used: Type; Grit size and the flow rate required 3. Target material: Composition of workpiece and mechanical properties such as hardness etc. 4. Mixing: Inlet angle; tube length, bore diameter; 5. Cutting: Angle of Attack; Stand of Distance (SOD); Traverse Speed