abrasive jet machining research paper

Abrasive Jet Machining- Research Review

Srikanth et al., International Journal of Advanced Engineering Technology, Vol. V/Issue II/April-June, 2014

7 Pages Posted: 19 Oct 2020

Venkata Sreekanath Desu

St. Martin's Engineering College

Date Written: June 01, 2014

Abrasive jet machining is an effective machining process for processing a variety of Hard and Brittle Material. And has various distinct advantages over the other non-traditional cutting technologies, such as, high machining versatility, minimum stresses on the work piece, high flexibility no thermal distortion, and small cutting forces. This paper presents an extensive review of the current state of research and development tin the abrasive jet machining process. Further challenges and scope of future development in abrasive jet machining are also projected. This review paper will help researchers, manufacturers and policy makers widely.

Keywords: versatility, flexibility, nontraditional

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Application of grey fuzzy logic in abrasive jet machining process

Feasibility of using wet abrasive jet machining to produce flat and crack-free micro-textures on reaction bonded silicon carbide, experimental investigation of µ-abrasive jet machining with dust collection mechanism, an integrated approach of simulation, modeling and computer-aided design of hot abrasive jet machining setup, effect of the threaded nozzle on delamination and surface texture of peek cf30 composite machined by abrasive jet.

Purpose The purpose of this study is to bring out the machining characteristics of abrasive jet machining on carbon fibre reinforced thermoplastic composites utilized in aerospace and biomedical applications. Biocompatibility materials such as carbon fibres and polyether thermoplastics, like polyether ether ketone (PEEK) are widely used in trauma and orthopaedic surgery. Due to the heterogeneity, layered construction of reinforcing phase bonds with a resin matrix and abrasiveness of the reinforcing fibre, traditional drilling of carbon fibre-reinforced composites (CFRPs) are always challenging task. Design/methodology/approach An investigation is carried out using abrasive jet machine for drilling PEEK filled with 30 Wt.% carbon fibre (CF 30) using threaded and unthreaded nozzle to study the effect of abrasive jet process variables on surface roughness (Ra) and delamination factor (DF). Pressure (P) and stand-off distance (SOD) as important technological abrasive jet factors were evaluated. It is found that higher abrasive jet pressure and minimum SOD maybe selected to achieve minimum delamination. Findings The study further reported that the threaded nozzle minimized the surface roughness by 43% and delamination factor up to 12%. Originality/value This study of experimenting and observing the machining characteristics of CF30 by using a threaded nozzle is being tried for the first time and the results are deliberated.

Abrasive Jet Machining for the Microprofile Control Patterning of Herringbone Grooves

Machining of aluminium nitride ceramic using developed hot abrasive jet machining: an experimental and simulation approach, selected methods and applications of anti-friction and anti-wear surface texturing.

The constant development of environmental protection causes the necessity to increase the efficiency of machines. By increasing the efficiency of machines, energy losses can be limited, leading to lower energy consumption. Friction reduction leads to an increase in efficiency and a decrease in wear. In this paper, selected surface texturing methods, such as burnishing and abrasive jet machining, with their limitations are presented. Thanks to those processes, various surface textures can be obtained. Examples of applications of these methods for friction and wear reduction are shown.

Performance evaluation of newly designed nozzle on abrasive jet machining characteristics of laminated composites

Purpose The purpose of the study is to machine the composites at lower machining time with higher accuracy without causing delamination. Design/methodology/approach Abrasive jet machining is the technology appropriate for machining composite materials to obtain good dimensional accuracy without causing de-lamination. The central composite design was followed in deciding the number of experiments to be carried out. Findings The influence of abrasive jet machining process parameters on machining time, material removal rate (MRR) and kerf characteristics were investigated. The experimental results proved the newly designed internal threaded nozzle increased MRR, thereby reducing the machining time. Originality/value Machining of glass fibre reinforced polymer (GFRP) is one of the challenging tasks given its non-linear and in-homogeneous properties. In this investigation, newly developed threaded and unthreaded nozzles in machining were used for making holes on the GFRP composites.

Fabrication and process analysis of working model of abrasive jet machining

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• DOI: 10.1007/s00170-024-13914-z
• Corpus ID: 270344228

Modeling the shape profile of the machining side trimmed by abrasive water jet

• Mingfeng Chen , Shijin Zhang , +1 author Zhiyuan Wu
• Published in The International Journal of… 7 June 2024
• Engineering, Materials Science

24 References

Research progress in abrasive water jet processing technology, experimental investigation and modelling of the kerf profile in submerged milling by macro abrasive waterjet, gaussian distribution-based modeling of cutting depth predictions of kerf profiles for ductile materials machined by abrasive waterjet, effect of state-dependent time delay on dynamics of trimming of thin-walled structures, investigation on kerf taper in abrasive waterjet machining of aluminium alloy 6061-t6, research on kerf error of aluminum alloy 6061-t6 cut by abrasive water jet, modelling of abrasive waterjet kerf in a double-layered structure, optimization of trimming process in cold forging of steel bolts by taguchi method, recent progress trend on abrasive waterjet cutting of metallic materials: a review, experimental and numerical investigation of the abrasive waterjet machining of aluminum-7075-t6 for aerospace applications, related papers.

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Monitoring equipment malfunctions in composite material machining: acoustic emission-based approach for abrasive waterjet cutting.

Graphical Abstract

1. Introduction

• The accidental reduction in the abrasive flow rate, whether partial or total, poses a significant challenge in AWJ cutting processes [ 19 ]. This reduction can occur due to various factors such as the inadvertent introduction of impurities into the abrasive delivery tank, the wear of the rubber tube used for feeding the abrasive, or the entry of water droplets into the abrasive tank. Unlike the capability to detect a complete absence of abrasive material, current AWJ equipment lacks a system capable of effectively detecting a decrease in the abrasive mass flow.
• The clogging of the cutting head with abrasive grits occurs when they partially or completely block the mixing tube [ 24 , 25 , 26 ]. As a result, the water jet is unable to exit through the mixing tube and may flow back up the abrasive tube, potentially reaching the abrasive hopper. This situation leads to heavy splashing, and although the cutting head moves, it fails to cut effectively.
• The orifice and focusing tube are subject to wear during abrasive waterjet machining [ 24 , 27 ]. The orifice is susceptible to sudden breakage, cracking, or tearing.
• A water pressure drop refers to a reduction in the force exerted by the water stream used in the AWJ process. Such a decrease can appear due to various factors, including leaks in the system, blockages in the water supply lines, or malfunctions in the pump mechanisms [ 26 ].

2. The Proposed Method for Monitoring Abrasive Waterjet Cutting

• Developing a smart monitoring/control system for detecting and predicting random machine malfunctions, which could damage the CM parts, also leads to a productivity and quality improvement, as well as a cost reduction.
• The variations in the AWJ energy and Acoustic Emission (AE) facilitate the verification of correct jet penetration. This ensures that the operator has selected the optimal combination of process parameters to achieve the required quality characteristics of the processed part.
• The implementation of state-of-the-art monitoring and control technologies boosts the competitiveness of companies using AWJ processing. The companies will be able to approach projects in high-end fields such as the automotive or aerospace industries, where the price of processed material is very high.
• The integration of the proposed monitoring technique within the framework of digitalization and Industry 4.0/5.0 constitutes the basis of advanced technologies and methodologies, such as Sensor Integration, Data Analytics and AI, Digital Twin Technology, Cloud Computing and Edge Computing, Integration with MES and ERP Systems, Human-Machine Interface (HMI), and Cybersecurity.

3. Materials and Methods

3.1. design of experiments, 3.2. equipment, 3.3. materials, 3.4. experimental results, 4. results and discussion, 4.1. the ae signal analysis, 4.2. mathematical modeling, 4.3. analysis of the influence of process parameters on the ae signal, 4.4. validation of the proposed method for monitoring awjc malfunctions, 5. conclusions.

• The development of an in situ energy-based monitoring method represents a significant advancement in AWJC process monitoring. By correlating the AWJ energy with the AE signals, this method offers real-time insights into the process dynamics, enabling the detection of anomalous events and potential equipment malfunctions. Mathematical models were developed for calculating the root mean square of the AE signal at the cutting head and at the workpiece. These models provide a normal level of AE RMS signal for different values of process parameters.
• The proposed monitoring technique enables the early detection of equipment malfunctions, 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. By promptly identifying and addressing these issues, manufacturers can minimize the risk of part rejection, material wastage, and production delays. This study examined the issue of an accidental reduction in the abrasive flow rate, outlining the pattern of this malfunction.
• The findings of this study have practical implications for industries utilizing AWJC for precision machining of composite materials. By implementing the proposed monitoring method, companies can improve the process reliability, quality assurance, and operational efficiency, ultimately enhancing the competitiveness in high-value sectors.
• Future developments in this monitoring approach could involve the integration of anomaly detection algorithms for automated fault diagnosis and process adjustment. Additionally, advancements in Industry 4.0 integration may lead to the development of smart software systems capable of real-time monitoring and analysis, further enhancing process efficiency and overall equipment effectiveness.

Author Contributions

Institutional review board statement, informed consent statement, data availability statement, conflicts of interest.

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Share and Cite

Popan, I.A.; Cosma, C.; Popan, A.I.; Bocăneț, V.I.; Bâlc, N. Monitoring Equipment Malfunctions in Composite Material Machining: Acoustic Emission-Based Approach for Abrasive Waterjet Cutting. Appl. Sci. 2024 , 14 , 4901. https://doi.org/10.3390/app14114901

Popan IA, Cosma C, Popan AI, Bocăneț VI, Bâlc N. Monitoring Equipment Malfunctions in Composite Material Machining: Acoustic Emission-Based Approach for Abrasive Waterjet Cutting. Applied Sciences . 2024; 14(11):4901. https://doi.org/10.3390/app14114901

Popan, Ioan Alexandru, Cosmin Cosma, Alina Ioana Popan, Vlad I. Bocăneț, and Nicolae Bâlc. 2024. "Monitoring Equipment Malfunctions in Composite Material Machining: Acoustic Emission-Based Approach for Abrasive Waterjet Cutting" Applied Sciences 14, no. 11: 4901. https://doi.org/10.3390/app14114901

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Optimizing Parameters of Ultrasonic Machining Using TOPSIS Method

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• L. Bongpai Konyak 16 ,
• Longshibemo Jami 16 ,
• Subhankur Dutta 16 &
• Amit Kumar Singh 16  

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Ultrasonic machining (USM) is an advanced machining process used for machining brittle and hard materials that can’t be machined using conventional methods. The most important advantage of USM is cutting precise holes of any shape in engineering ceramics, quartz glass, diamond, etc. USM is also used for machining the materials used in aerospace, defense, electronics, automotive, bio-engineering, etc. Here Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) is used for getting the best alternative depending on their relative shortest distance to the ideal solution. Quartz glass with size (5 × 45 × 45) mm has been used for the current work. The parameter setting with ultrasonic power of 55%, tool feet rate of 0.75 mm/min, and tool rotational speed of 5000 rpm were found as closest to the ideal solution. The grooves on the machine surface were formed by continuous strikes of abrasive material (diamond with a sharp cutting edge).

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Konyak, L.B., Jami, L., Dutta, S., Singh, A.K. (2024). Optimizing Parameters of Ultrasonic Machining Using TOPSIS Method. In: Sudarshan, T.S., Sharma, A.K., Misra, R., Patowari, P.K. (eds) Recent Advancements in Mechanical Engineering. ICRAMERD 2022. Lecture Notes in Mechanical Engineering. Springer, Singapore. https://doi.org/10.1007/978-981-97-0900-7_4

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