Role of Process Parameters on Pocket Milling with Abrasive Water Jet Machining Technique
Abrasive Water Jet Machining is an unconventional machining process well known for machining hard to cut materials. The primary research focus on the process was for through cutting and a very limited literature is available on pocket milling using AWJM. The present work is an attempt to use this process for milling applications considering a set of various process parameters. Four different input parameters, which were considered by researchers for part separation, are selected for the above application, i.e., abrasive size, flow rate, standoff distance and traverse speed. Pockets of definite size are machined to investigate surface roughness, material removal rate and pocket depth. Based on the data available through experiments on SS304 material, it is observed that higher traverse speeds gives a better finish because of reduction in the particle energy density and lower depth is also observed. Increase in the standoff distance and abrasive flow rate reduces the rate of material removal as the jet loses its focus and occurrence of collisions within the particles. ANOVA for individual output parameter has been studied to know the significant process parameters.
[1] A. W. Momber, R. Kovacevic, H. Kwak, “Alternative method for the
evaluation of the abrasive water-jet cutting of grey cast iron”, Journal of
Material Processing Technology, 1997, Vol. 65, Issue 1-3, pp. 65-72.
[2] R. Kovacevic, “Surface texture in abrasive waterjet cutting”, 1991,
Journal of Manufacturing Systems, Vol. 10, Issue 1, pp. 32-40.
[3] I. Finnie, “Erosion of surfaces by solid particles”, 1960, Wear, Vol. 3,
pp. 87-103.
[4] J. G. A. Bitter, “A study of wear phenomenon Part I”, 1963, Wear, Vol.
6, pp. 5-21.
[5] J. G. A. Biter, “A study of wear phenomenon Part II”, 1963, Wear, Vol.
6, pp. 169-190.
[6] R. Kovacevic, “Monitoring the depth of abrasive water jet penetration”,
1992, International Journal of Machine Tools & Manufacture, Vol. 31,
No.5, pp. 725-736.
[7] F. L. Chen, E. Siores, W. C. K. Wong, “Optimizing abrasive waterjet
cutting of ceramic materials”, 1998, Journal of Material Processing
Technology 74, pp. 251-254.
[8] F. L. Chen, E. Siores, “The effect of cutting jet variation on striation
formation in abrasive water jet cutting”, 2001, International Journal of
Machine Tool & Manufacture, pp. 1479-1486.
[9] F. L. Chen, J. Wang, E. Lemma, E. Siores, “Striation formation
mechanisms on the jet cutting surface”, 2003, “Journal of Material
Processing Technology, 213-218.
[10] K. M. C. Ojmertz, “Analysis of surfaces produced by abrasive water jet
milling technique”, 1996, C. Gee (Ed), Jet Cutting Technology,
Mechanical Engineering, Publishers, Bury St. Edmunds, pp. 753-768.
[11] R. T. Deam, E. Lemma, D. H. Ahmed, “Modelling of abrasive water jet
cutting process”, 2004, Wear, 257, pp. 877-891.
[12] M. Hashish, “Milling with Abrasive-Waterjets-A Preliminary
Investigation”, 1987, Proc. of the 4th U.S. Water Jet Conference,
Berkeley, California, August 26-28, pp. 1-20.
[13] M. Hashish, “Controlled depth milling of isogrid structures using
AWJS”, 1994, Reprinted from PED-Vol. 86-1, Manufacturing Science
and Engineering, Book No. G0930A, pp. 413-419.
[14] G. Fowler, P. H. Shipway, I. R. Pashby, “A technical note on grit
embedment following abrasive water jet milling of titanium alloy”,
2005, Journal of Material Processing Technology, 159, pp. 356-368.
[15] G. Fowler, P. H. Shipway, I. R. Pashby, “Abrasive Water-jet controlled
depth milling of TiAl4V, alloy-an investigation of role of jet-workpiece
traverse speed and abrasive grit size on the characteristics of the milled
surface”, 2005, Journal of Material Processing Technology, 161, pp.
407-414.
[16] G. Fowler, P. H. Shipway, I. R. Pashby, “The effect of particle hardness
and shape when abrasive jet milling of titanium alloy Ti6Al4V”, 2009,
Wear, Vol. 266, Issues 7-8, pp. 613-620.
[17] J. Wang, W. C. K. Wong, “A study of abrasive waterjet cutting of
metallic coated sheet steel”, 1999, Intl. Journal of Machine Tools &
Manufacture, Vol. 39, pp. 855-870.
[18] M. Ramulu, D. Arola, “The influence of abrasive water jet cutting
conditions on the surface quality of graphite/epoxy laminates”, 1994,
Intl. Journal of Machine Tools & Manufacture, Vol. 34, Issue 3, pp.
295-313.
[1] A. W. Momber, R. Kovacevic, H. Kwak, “Alternative method for the
evaluation of the abrasive water-jet cutting of grey cast iron”, Journal of
Material Processing Technology, 1997, Vol. 65, Issue 1-3, pp. 65-72.
[2] R. Kovacevic, “Surface texture in abrasive waterjet cutting”, 1991,
Journal of Manufacturing Systems, Vol. 10, Issue 1, pp. 32-40.
[3] I. Finnie, “Erosion of surfaces by solid particles”, 1960, Wear, Vol. 3,
pp. 87-103.
[4] J. G. A. Bitter, “A study of wear phenomenon Part I”, 1963, Wear, Vol.
6, pp. 5-21.
[5] J. G. A. Biter, “A study of wear phenomenon Part II”, 1963, Wear, Vol.
6, pp. 169-190.
[6] R. Kovacevic, “Monitoring the depth of abrasive water jet penetration”,
1992, International Journal of Machine Tools & Manufacture, Vol. 31,
No.5, pp. 725-736.
[7] F. L. Chen, E. Siores, W. C. K. Wong, “Optimizing abrasive waterjet
cutting of ceramic materials”, 1998, Journal of Material Processing
Technology 74, pp. 251-254.
[8] F. L. Chen, E. Siores, “The effect of cutting jet variation on striation
formation in abrasive water jet cutting”, 2001, International Journal of
Machine Tool & Manufacture, pp. 1479-1486.
[9] F. L. Chen, J. Wang, E. Lemma, E. Siores, “Striation formation
mechanisms on the jet cutting surface”, 2003, “Journal of Material
Processing Technology, 213-218.
[10] K. M. C. Ojmertz, “Analysis of surfaces produced by abrasive water jet
milling technique”, 1996, C. Gee (Ed), Jet Cutting Technology,
Mechanical Engineering, Publishers, Bury St. Edmunds, pp. 753-768.
[11] R. T. Deam, E. Lemma, D. H. Ahmed, “Modelling of abrasive water jet
cutting process”, 2004, Wear, 257, pp. 877-891.
[12] M. Hashish, “Milling with Abrasive-Waterjets-A Preliminary
Investigation”, 1987, Proc. of the 4th U.S. Water Jet Conference,
Berkeley, California, August 26-28, pp. 1-20.
[13] M. Hashish, “Controlled depth milling of isogrid structures using
AWJS”, 1994, Reprinted from PED-Vol. 86-1, Manufacturing Science
and Engineering, Book No. G0930A, pp. 413-419.
[14] G. Fowler, P. H. Shipway, I. R. Pashby, “A technical note on grit
embedment following abrasive water jet milling of titanium alloy”,
2005, Journal of Material Processing Technology, 159, pp. 356-368.
[15] G. Fowler, P. H. Shipway, I. R. Pashby, “Abrasive Water-jet controlled
depth milling of TiAl4V, alloy-an investigation of role of jet-workpiece
traverse speed and abrasive grit size on the characteristics of the milled
surface”, 2005, Journal of Material Processing Technology, 161, pp.
407-414.
[16] G. Fowler, P. H. Shipway, I. R. Pashby, “The effect of particle hardness
and shape when abrasive jet milling of titanium alloy Ti6Al4V”, 2009,
Wear, Vol. 266, Issues 7-8, pp. 613-620.
[17] J. Wang, W. C. K. Wong, “A study of abrasive waterjet cutting of
metallic coated sheet steel”, 1999, Intl. Journal of Machine Tools &
Manufacture, Vol. 39, pp. 855-870.
[18] M. Ramulu, D. Arola, “The influence of abrasive water jet cutting
conditions on the surface quality of graphite/epoxy laminates”, 1994,
Intl. Journal of Machine Tools & Manufacture, Vol. 34, Issue 3, pp.
295-313.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:65448", author = "T. V. K. Gupta and J. Ramkumar and Puneet Tandon and N. S. Vyas", title = "Role of Process Parameters on Pocket Milling with Abrasive Water Jet Machining Technique", abstract = "Abrasive Water Jet Machining is an unconventional machining process well known for machining hard to cut materials. The primary research focus on the process was for through cutting and a very limited literature is available on pocket milling using AWJM. The present work is an attempt to use this process for milling applications considering a set of various process parameters. Four different input parameters, which were considered by researchers for part separation, are selected for the above application, i.e., abrasive size, flow rate, standoff distance and traverse speed. Pockets of definite size are machined to investigate surface roughness, material removal rate and pocket depth. Based on the data available through experiments on SS304 material, it is observed that higher traverse speeds gives a better finish because of reduction in the particle energy density and lower depth is also observed. Increase in the standoff distance and abrasive flow rate reduces the rate of material removal as the jet loses its focus and occurrence of collisions within the particles. ANOVA for individual output parameter has been studied to know the significant process parameters.
", keywords = "Abrasive flow rate, surface finish, abrasive size, standoff distance, traverse speed.", volume = "7", number = "10", pages = "2037-6", }
