FINAL REWIEW

MACHINABILITY STUDY OF ABRASIVE WATER JET CUTTING

PROCESS ON ALUMINIUM ALLOYS 6083

PROJECT GUIDE, PROJECT BY,

MR.C.JOEL,M.E.(Ph.D) Saaswath Kanna K.V
ASSISTANT PROFESSOR
Vignesh S
Udhayaprakash U
 ABSTRACT
Abrasive Water Jet (AWJ) Machining is a recent non-traditional
machining process.
The machining of materials with extreme brittle is very difficult
in traditional machining processes (Turning, Drilling, Milling
and Shaping). Non-traditional machining is fulfilled with these
problems with absence of sharp cutting tools.
Abrasive water jet cutting of material involves the effect of a
high velocity jet of water with entrained abrasive
particles(Garnet, Silicon carbide, Diamond etc) on to material
to be cut.
The materials such as AA6083 alloy is selected in this study
using AWJ process for investigating its mechanical and
metallurgical behaviors.

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 ABSTRACT
The experiment is conducted by varying input parameters such
as Abrasive Mass Flow rate, Stand-off Distance, Transverse
Speed and Water Pressure.
The outputs considered for this study is Micro-structure, Surface
Roughness (SR) & Hardness.
The objective of optimization is to optimize the micro-structure,
hardness and minimize in surface roughness
In this study, the best combination of optimal parameter is
identified based on the different tools in optimization technique,
ANOVA.

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 RESEARCH OBJECTIVES
To investigate the AWJ cutting performance by varying the level of
Abrasive feed, Stand-off distance and Nozzle speed on cutting of
AA6083.
To analyze the cutting performance characteristics such as material
removal rate, surface roughness and hardness.
To find the optimal parameter, using ANOVA.

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ABRASIVE WATER JET MACHINING

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 WORKING
 First water is filled in water reservoir. It provides water for
cutting operation.
 A pump sucks water from water reservoir and send it to
intensifier.
 Intensifier increases the water pressure from 4 bar to 4000
bars. It sends water to accumulator which store some
pressurize water.
 Now this high pressure water enters into nozzle. This nozzle
convert high pressure of water into high velocity jet.
 This water jet send to strike at work surface. It erode metal
from the contact surface. Thus metal removal take place
 ADVANTAGES OF AWJ CUTTING

Minimum cutting forces on work-piece with high accuracy.

High surface finish.
Limited tooling requirements.
Thermal distortion is eliminated.
AWJ can cut all kind of materials including glass, reflective, etc.,
Since cutting is in cold process, there is no change in material
properties .
AWJ has no harmful vapors during cutting process.

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 APPLICATIONS OF ABRASIVE WATERJET
AWJM is suitable for machining heat sensitive material like silicon,
gallium because the heat generation during the machining is very
low.

Used in various industries like mining, automotive and aerospace for

performing cutting, shaping etc

For removal of parting lines from injection moulded parts.

The materials which are commonly machined by AWJM are rubber,

textiles, plastics, foam, leather.
EXPERIMENTAL SETUP
 MACHINE SPECIFICATION
Machine Specifications Ranges
Water Jet diameter (Nozzle dia.) 1.1 mm
Water Pressure (P) 3200 bar
Abrasive Flow Rate 0 to 700
Transverse Speed 10 to 25 (or) 15 to 30
Stand-Off Distance 1 to 3 mm
Type of Abrasive with specifications Garnet, 80 Mesh
Type of Water used RO Water
Abrasive Ratio (Mixture) 1:3 (Abrasive: Water)
Nozzle Water Flow Rate 3200 bar
Speed 3.5 Lt/min
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 Parent Material(AA6083)
Cutting Process: After Cutting:
 LITERATURE REVIEW
Author Title Discussion Year
Verma et al Modelling and analysis of abrasive The abrasive water jet experiments
water jet machining of AA2014 alloy was conducted on the AA2014
with Al2O3 abrasive using fuzzy logic aluminium alloy with the parameters
2019
traverse speed, standoff distance,
pressure and mass flow rate and depth
of cut was measured as the response.
The cutting process was also studied
Modelling and multi-objective by studying the surface roughness,
optimization of surface roughness and kerf taper angle using the design of
Parikshit et al 2018
kerf taper angle in abrasive water jet experiments. RSM technique is used
machining of steel to identify the optimal value based on
the input parameters
The work aims to understand the role
Experimental analysis and of traverse speed and pressure to
Bhandarkar et characterize the machined surface to
characterization of abrasive water jet 2019
al avoid any cracks while machining.
machining of Inconel 718

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 Author Title Discussion Year

An experimental study on abrasive waterjet A study was done by investigating the titanium alloys
Alberdi et al cutting of CFRP/Ti6Al4V stacks for drilling using abrasive water jet cutting process by analyzing 2016
operations the kerf profile, surface roughness and taper angle .

A study was focused on the study of depth of

Effect of process parameters on depth of
penetration on AZ91 magnesium alloy and optimal
penetration and topography of AZ91
Niranjan et al parameter. Surface roughness is analyzed with 2018
magnesium alloy in abrasive water jet
different transverse speeds and studied the
cutting
morphology of cut surfaces

The machinability studies were also focused on

Machinability Studies of Aluminium 6061 cut studying the depth of cut by varying the input
Prabhuswamy et al 2018
by Abrasive Water Jet parameters in 6061 aluminium alloys and studied its
surface morphology

The study on AA6082 material using AWJ process

Effects of machining parameters on surface
and examined the surface roughness and
roughness and macro surface characteristics
Kartal et al characteristics of macro surface. The influence MRR 2017
when the machining of Al-6082 T6 alloy
is analysed from the input parameters such as
using AWJT
spindle speed, abrasive flow rate, stand-off distance.
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LITERATURE REVIEW cont..
Author Title Discussion Year
Verma et al Modelling and analysis of abrasive The abrasive water jet experiments was
water jet machining of AA2014 alloy conducted on the AA2014 aluminium alloy with
with Al2O3 abrasive using fuzzy logic the parameters traverse speed, standoff distance,
2019
pressure and mass flow rate and depth of cut was
measured as the response.

Rajkamal Shukla and Dinesh Experimentation investigation of The experimental study for the machining of the
Singh abrasive water jet machining AA631-T6 content with the Taguchi technique.
parameters using Taguchi and The paper tested with optimization of particle
Evolutionary optimization techniques swarm, firefly algorithm, artificial bee colony,
2017
virtual rinsing, black hole, biogeography and the
non-dominated genetic sorting algorithm.

Munuswamy Naresh Babu Exploration on Kerf-angle and Surface
and Nambi Muthukrishnan Roughness in Abrasive Waterjet
Machining using Response Surface
Method
The effect process parameters like feed rate,
water pressure, standoff distance and abrasive
flow rate on the surface roughness and kerf-angle
of AISI 1018 mild steel experimentally. The 2017
experiments were performed under Taguchi’s
L27 orthogonal array.

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SCHEME OF RESEARCH
 SELECTION OF MATERIAL
ALUMINIUM ALLOY-AA6083

Aluminium alloy 6082 is a medium strength alloy with excellent

corrosion resistance.
It has the highest strength of the 6000 series alloys.
Due to the presence of silicon, magnesium and manganese it offers
better machinability
As a relatively new alloy, the higher strength of 6082 is that it
replaces 6061 in many applications

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 INTRODUCTION ON AA6083 MATERIAL
Chemical Composition of AA6083 Aluminium alloy
Mechanical Properties of AA6083 Aluminium alloy
Element
Si Fe Cu Mn Mg Zn Cr Ti Al
Properties Value s
Density 2.81 g/cc Weight Balan
0.4 0.35 0.1 0.1 0.7 0.1 0.1 0.1
Ultimate Tensile % ce
228 MPa
Strength
Tensile Yield
103 MPa
Strength
Shear Strength 331 MPa
Fatigue Strength 159 MPa
Modulus of
71.7 GPa
Elasticity
Shear Modulus 26.9 GPa

Microstructural observations in AA6083 base material

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 EXPERIMENTAL DETAILS
AWJ CUTTING PARAMETERS AND ITS LEVELS
A Box-Behnken design with three factors and three levels was selected and design matrix
consisting of 15 runs with a three center points was listed in Table. The upper and lower limits of
the parameters are generated with +1 and −1, respectively.

Levels
No. Factors Unit Notation
-1 0 1
1 Abrasive Feed g/min A 250 300 350
2 Stand-off Distance mm B 2 3 4

3 Transverse Speed mm/min C 32 36 44

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EXPERIMENTAL DETAILS cont..
Design matrix and its level of factors

ABRASIVE TRANSVERSE
SL.NO SOD (mm)
FEED(GPM) SPEED (mm/min)
1. 300 1 32
2. 350 1 32
3. 300 1.5 36
4. 350 1.5 36
5. 300 2 44
6. 400 2 44
7. 300 4 24
8. 350 4 24
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SURFACE ROUGHNESS OUTPUTS:

Equipment Used: Surface Roughness Tester(Ra Value)

Sample No Observed Values(microns) Average Value(microns)

1 4.55, 4.45, 4.76, 4.72 4.62

2 4.37, 4.43, 4.37, 4.17 4.33

3 3.13, 3.76, 3.84, 4.24, 4.01 3.79

4 3.67, 3.53, 3.17, 4.56, 4.12 3.81

5 4.53, 4.74, 4.84, 4.38, 4.08 4.514

6 6.25, 5.85, 5.35, 4.57, 4.50 5.30

7 4.48, 4.54, 4.68, 4.85, 4.30 4.57

8 5.31, 4.69, 4.56, 4.85, 4.30 4.77

HARDNESS OUTPUT:

Surface Hardness/HBW/5mm ball/Load 500kg

Test Method: ASTM E10
Sample No Observed Value Average Value(BHN)
1 95.9, 84.7 90.33
2 96.3, 90.4 93.39
3 91.1, 89.8 90.45
4 97.5, 102 99.75
5 102, 101.5 101.53
6 98.25, 99.75 99
7 103.4, 100.5 101.95
8 97.85, 99.15 98.5
MICRO-STRUCTURE OUTPIT:
Results:

• For the different experimental input parameters, the output

parameters are noted.
• The observed output parameters are optimized using tools(GRM,
RSM and TBLO) and the optimal outputs are predicted.
• The confirmation experiment is conducted and the better input
parameters are finalised.
THANK YOU