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Introduction
The addition of abrasives to the water jet enhanced MRR and produced
cutting speeds between 51 and 460 mm/min.
Zheng et al. (2002) claimed that the abrasive water jet is hundreds of
times more powerful than the pure water jet.
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WJM pure
Direct pumping
Indirect pumping
Bypass pumping
In all the above variants, the basic methodology remains the same.
Basic Methodology
Such a high velocity water jet can machine thin sheets/foils of aluminium,
leather, textile, frozen foods, etc.
Problem in WJM as the high velocity water jet is discharged from the
orifice, the jet tends to entrain atmospheric air and flares out decreasing
the machining ability.
Hence, stabilizers (long chain polymers) are added to water (WJM with
stabilizer).
In AWJM, abrasive particles are added to the water jet to enhance its
cutting ability by many folds.
Such high velocity abrasive jet can machine almost any material.
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Paint removal
Cleaning
Mass Immunization
Surgery
Peening
Pocket Milling
Polymers
Honeycombs
Concrete
Stone Granite
Wood
Reinforced plastics
Thus, WJM is typically used to cut so called softer and easy-tomachine materials like thin sheets and foils, non-ferrous metallic alloys,
wood, textiles, honeycomb, polymers, frozen meat, leather etc.
Other than cutting (machining) high pressure water jet also finds
application in paint removal, cleaning, surgery, peening to remove
residual stress etc.
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Applications Contd.
AWJM can as well be used besides cutting for pocket milling, turning,
drilling, etc.
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Applications Contd.
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AWJM - Elements
AWJM accelerates a jet of water (70 percent) and abrasive (30 percent)
from 4.2 bar up to a velocity of 30 m/s.
Silicon carbides, sand (SiO2), corundum, and glass beads of grain size 10
to 150 m are often used as abrasive materials.
Using such a method, burrs of 0.35 mm height and 0.02 mm width left in
steel component after grinding are removed by the erosive effect of the
abrasives while water acts as an abrasive carrier.
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AWJM - Elements
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Machining System
In AWJM, the water jet accelerates abrasive particles, not the water, to
cause the material removal.
After the pure water jet is created, abrasives are added using either the
injection or suspension methods.
The important parameters of the abrasives are the material structure and
hardness, grain shape, size, and distribution.
Filters
Water delivery
Mixing chamber
Cutting nozzles
Intensifier
Catcher
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Intensifier
Intensifier Contd.
Thus, if the hydraulic pressure is set as 100 bar and area ratio is 40, p w =
100 x 40 = 4000 bar.
The water may be directly supplied to the small cylinder of the intensifier.
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Intensifier Contd.
As the larger piston changes direction within the intensifier, there would
be a drop in the delivery pressure.
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Other Elements
High-pressure water is then fed through the flexible stainless steel pipes
to the cutting head.
Such pipes carry water at 4000 bar (400 MPa) with flexibility
incorporated in them with the help of joints, but without any leakage.
Water carried through the pipes is brought to the jet former or cutting
head.
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Cutting Heads
Schematic View
Photographic View
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The velocity of the water jet thus formed can be estimated, assuming no
losses as vwj = (2pw / w)1/2 using Bernoullis equation.
Where, pw and w are pressure and density of water respectively.
In WJM this high velocity water jet is used for the required application
where as in AWJM it is directed into the mixing chamber.
As the high velocity water is issued from the orifice into the mixing
chamber, low pressure (vacuum) is created within the mixing chamber.
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Mixing Chamber
Finally the abrasive water jet comes out of focussing tube or nozzle.
When the jet finally leaves the focussing tube, both phases, water and
abrasive, are assumed to be at same velocity.
Mixing Chamber
Abrasive particles during mixing try to enter the jet, but they are reflected
away due to interplay of buoyancy and drag force.
They go on interacting with the jet and the inner walls of the mixing tube,
until they are accelerated using the momentum of the water jet.
In entrained AWJM, the abrasive water jet, which finally comes from the
focussing tube or nozzle, can be used to machine different materials.
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Catcher
Once the abrasive jet has been used for machining, they may have
sufficiently high level of energy depending on the type of application.
Catcher is used to absorb the residual energy of the AWJ and dissipate
the same.
Three types of catcher water basin type, submerged steel balls and TiB 2
(Titanium Diboride extremely hard) plate type.
Moreover the catcher can be of (a) pocket type or (b) line type.
Pocket type the catcher basin travels along the jet (along x and y axes).
Line type the catcher basin travels along one axis and its length covers
the entire width of the other axis of the CNC table.
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Catcher
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Where
u
cd
do
pw
Pressure of water
w -
Density of water
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Thus, in WJM and AWJM the following are the important product quality
parameters.
Striation formation.
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Process Capabilities
Process variables
Pressure
Nozzle diameter
Standoff distance
Surface roughness depends on the workpiece material, grit size, and type
of abrasives.
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Fine grains are used for machining soft metals to achieve better
roughness
This results in higher grain speed and increased metal removal rate.
Moreover, the carrier liquid spreads over the surface filling its cavities
and forming a film that impedes the striking action of the grains.
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Published Results
Kaczmarek (1976) showed that the use of water air jet permits one to
obtain, on average, a roughness number higher by one, as compared with
the effect of an air jet.
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Advanced water jet and AWJ machines are now available where the
computer loads a CAD drawing from another system.
The computer determines the starting and end points and the sequence of
operations.
The operator then enters the material type and tool offset data.
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