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Investigation on surface roughness and kerf analysis in abrasive water jet machining of silicon carbide

Hynes N.R.J., Asirvatham A.D., Sankaranarayanan R., Raja S., Benita B., Atchaya J.

Archives of Materials Science and Engineering

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2023

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Vol. 120, nr 1

30--35

EN

Purpose: Machining silicon carbide (SiC) is challenging due to its brittle and maximum tensile nature. Lapping or laser beam are done with a high cost of manufacturing and low material removal rates. Water abrasive jet cutting is a promising candidate since the machining temperatures and processing force of ceramics are extremely low. Investigation into the abrasive water jet machining of silicon carbide is carried out in the present work. Design/methodology/approach: The variations in traverse speed while abrasive water jet cutting of silicon carbide and its effect on the surface roughness and kerf characteristics are studied. Silicon Carbide abrasive material is used as garnet consisting of 80 mesh. The surface roughness was calculated along with the depth of the cut made during the processing. Findings: The outcomes demonstrated that the traverse speed is more effective upon the surface roughness and is an important factor that damages the top kerf width and the kerf taper angle. Research limitations/implications: Based on the hardness and thickness of the SiC plate, the taper angle is high, and for a feed rate of 10 mm/min, the surface roughness is low. Less thickness of the SiC plate could have a lower taper angle than with high thickness. The erosive force is provided by abrasive material along with the jet stream. Practical implications: Water abrasive fine jet could effectively machinate silicon carbide ceramic material with a better surface finish accurately. Suitable surface roughness with higher productivity can be attained with medium traverse speed. Originality/value: The effect of process parameters on kerf taper angle and top kerf width in the abrasive water jet machining of silicon carbide is explored, considering surface roughness as an important output parameter.

2

Multi-Criteria Decision Making of Abrasive Water Jet Machining Process for 2024-T3 Alloy Using Hybrid Approach

Khudhir Waqass S., Abbood Mohanad Qusay, Shukur Jalil J.

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no 5

155--162

EN

Abrasive Water Jet Machining (AWJM) is one of the most environmentally friendly non-conventional machining processes, which can be employed to cut hard and thin materials without any thermal effects. In this study, the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) has been combined with the Entropy method and employed to find out the multi-criteria decision-making of process parameters. Experimental investigations have been conducted to evaluate the performance of the AWJM process in terms of surface roughness (Ra) and kerf angle (Ka). The selected process parameters are a stand-off distance (SOD), traverse speed (TS), and abrasive flow rate (AFL), whereas the AL-alloy 2024-T3 was selected as the work piece material. The image process technique has been utilized to measure the values of the Ka. The results demonstrate that the optimal solutions of the AWJM process, which give the smallest value of Ra and minimizes Ka, are 2mm, 20mm/min, and 100 g/min, for SOD, TS, and AFL respectively.

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Badania wpływu warunków cięcia strugą wodno-ścierną wyrobów kompozytowych wzmocnionych włóknem szklanym na ich właściwości wytrzymałościowe

Chatys R., Spadło S., Chatys I.

Zeszyty Naukowe Politechniki Świętokrzyskiej. Nauki Techniczne

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2012

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Z. 17

28-42

PL

W artykule przedstawiono wyniki badań wpływu warunków cięcia strugą wodno-ścierną (AWJM - Abrasive Water Jet Machining) wyrobów kompozytów z zastosowaniem różnych prędkości strugi na właściwości mechaniczne laminatu 2-kierunkowego. Badaniom poddano kompozyty o osnowie poliestrowej (Polimal 109-32K) formowane metodą infuzji oraz metodą kontaktową. Stwierdzono największą wydajność cięcia przy próbkach ciętych strumieniem wodno-ściernym pod kątem 45°, których wartości Rm i E polepszyły się odpowiednio o 19% i 7% niż ciętych CNC. Przy szacowaniu właściwości mechanicznych w modelu założono, że zniszczenie próbek wyciętych z laminatu szklanego przy różnych prędkościach cięcia odbywało się poprzez destrukcję krytycznej warstwy, której bardziej stabilne właściwości mechaniczne odnotowano przy cięciu z prędkością 3 m/min.

EN

The paper presents the results of the impact of cutting conditions of abrasive water jet (AWJM - Abrasive Water Jet Machining) of composites with different jet velocity on mechanical properties of 2-directional laminate. Subjected to no examination of warp polyester composites (Polimal 109-32K) and infusion molded by contact. It was found the highest cutting performance with samples cut stream of water and sand at an angle of 45°, where the value of Rm and E improved respectively by 19 and 7% less than the cut CNC (Computerized Numerical Control). When estimating the mechanical properties of clarity in the model assumes that the destruction of samples cut from the laminate glass with different cutting speeds takes place through the destruction of the critical layer, where a more stable mechanical properties were in the cutting speed of 3 m/min.

4

Tribological aspects of some materials abrasive-water jet cutting

Holka H., Matuszewski M., Musiał J., Styp-Rekowski M.

Journal of Machine Engineering

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2012

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Vol. 12, No. 2

46--52

EN

This article presents results of comparative studies into the roughness (very significant tribological factor) of surfaces cut using the AWJM method. Cutting was performed on samples made of quenched and tampered alloy steel (1.2080), plastic (polyamide PA6) and mineral material (syenite). Variable parameters in the cutting process included: jet pressure and feed. As a result of measurements involving selected roughness parameters (Ra, Rz and Rq), it was discovered that the majority of variable factors had a significant effect on the cut surface roughness. It was also demonstrated that the contact method measurements cannot be performed with regard to plastics because the results are characterised by a very great scatter of results values, making them unreliable.

5

Niekonwencjonalne technologie hydrostrumieniowe

Borkowski J., Borkowski P.

Mechanik

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2011

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R. 84, nr 12

XVI-XVII

PL

Rola i przykłady nowatorskich, wysokociśnieniowych technologii hydrostrumieniowych z zastosowaniem wielofazowej strugi wodnej.

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Finite element analysis of the interaction between an AWJ particle and a polycrystalline alumina ceramic

Gudimetla P., Yarlagadda P. K. D. V.

Journal of Achievements in Materials and Manufacturing Engineering

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2007

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Vol. 23, nr 1

7-14

EN

Purpose: Abrasive waterjet cutting involves use of a high pressure, abrasive laden waterjet at transsonic speeds to cut difficult-to-machine materials. The jet-material interaction depends on the nature of the material being cut, such as ductile or brittle. The brittle regime involves the generation and propagation of microcracks due to impact and many theories have been proposed in this regard. We aim to resolve the nature of the generation and propagation of cracks in such phenomena using the finite element analysis methodology. Design/methodology/approach: A 3-dimensional FE model was set up using PATRAN. The alumina ceramic was modelled as a 1-mm cube while a 0.1mm diameter half sphere was used to model a single abrasive particle. The system was imported into ABAQUS and an explicit analysis was performed. The element deletion method was used after invoking a failure criterion to estimate the number of elements removed due to a single impact. The aggregate volume of eroded material was then calculated by multiplying the number of elements removed with the volume of each element. The results of the FEA were compared with the brittle model proposed by Kim & Zeng. Findings: The results of the FEA indicate that mixed-mode failure is the most common form of failure in such interactions. The volume of material removed per impact from the FE results is close to 16% of those predicted by Kim & Zeng's model. Research limitations/implications: The finite element framework presented is idealized for the case of regular cubes based on a set of assumptions. Originality/value: This finite element approach is a good tool to study the nature of interaction between a microscopic particle and a brittle material and accurately predict the erosion mechanisms in such interactions.

7

Basis of three dimensional material forming using high-pressure abrasive-water jet controlled by virtual image luminance.

Borkowski P., Żukociński T.

Advances in Manufacturing Science and Technology

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2006

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Vol. 30, nr 1

53-62

EN

Superficial three dimensional material forming based on flat virtual image (picture) luminance is a new, original application of high-pressure abrasive-water jet forming. In article are described basis of three-dimensional forming of ceramic and rock materials by using scanning method of high-pressure abrasive-water jet in conjunction with deep and jet velocity parameters. It was built a control system and developed adequate algorithms allowing the 3D sculpturing operation of different complex objects to be mechanized.

PL

Powierzchniowe kształtowanie przestrzenne materiałów na podstawie luminancji odwzorowywanego wirtualnego obrazu płaskiego (fotografii) jest nowym, oryginalnym zastosowaniem obróbki wysokociśnieniową strugą wodno-ścierną. W pracy omówiono podstawy przestrzennego kształtowania materiałów ceramicznych i skalnych metodą wierszowania przejść wysokociśnieniowej strugi wodno-ściernej w warunkach sprzężenia parametrów głębokości i prędkości posuwowej strugi. Opracowano urządzenia sterujące i algorytmy tego rodzaju odwzorowania, pozwalające na zmechanizowanie operacji rzeźbienia 3D różnych złożonych obiektów.

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Nowe efektywne konstrukcje urządzeń do obróbki wysokociśnieniową strugą wodną i wodno-ścierną.

Oczoś K.E., Łabudzki R.

Mechanik

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2000

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R. 73, nr 12

819-823

PL

W pracy zasygnalizowano - na tle obecnego rozwoju obróbki wysokociśnieniową strugą wodną i wodno-ścierną - dokonujący się postęp w zakresie rozwiązań konstrukcyjnych urządzeń do realizacji tej perspektywicznej metody kształtowania materiałów metalowych i niemetalowych.

EN

The paper presents - on the background of actual state of the art in respect to water jet and abrasive water jet machining - the development in the area of design solutions concerning the equipment for realisation of this perspective method of metallic materials cutting.