3/6/2074

Water-Jet
Machining
Commercial CNC water
jet
machining system and
cutting heads
3161201"4
Application WJM & AWJM
Application
.
Paint removal
.
Cleaning
.
Cutting soft materials
.
Cutting frozen meat
.
Textile, Leather industry
.
Mass lmmunization
.
Surgery
.
Peening
.
Cutting
.
Pocket Milling
.
Drilling
.
Turning
.
Nuclear Plant Dismantling
Materials
.
Steels
.
Non-ferrous alloys
.
Ti alloys, Ni- alioys
.
Polymers
.
Honeycombs
"
Metal Matrix Composite
.
Ceramic Matrix Composite
.
Concrete
.
Stone
-
Granite
.
Wood
.
Reinforced plastics
.
Metal Polymer Laminates
.
Glass Fibre Metal Laminates
Examples of various parts produced
wate r-jet cutting process.
31612014
,e!
I lt f- r';ot:,u:
\i!igl--..,*"
Water-Jet
Cutting Process
(bi (r)
(a) Schematic illustration of the water-jet machining process. (b) A computer-
controlled water-jet cutting machine cutting a granite ptate. (c) Examples of various
Schematic set-up
of AWJM
1. LP Boosler
2. Hydraulic drive
3. Additive mixer
4- Direction conrrol
5. lnten6ifier
5A-LP lntensifier
58.HP lntsilsifisr
6. Accumulator
lntensifier
-
Schematic
ii
I',
i*
3/6/}a14
APPLICATION
The applications and materials, which are generally
machined using WJ and AWJ, are given
below:
Application
e
Paint renroval
.
Cleaning
.
Cutting soft materials
.
Cutting f rozen meat
"
Textile, Leather industry
.
Mass lmrnunization
.
Surgery
,
Peening
r
Cutting
"
Pocket Milling
.
Drilling
.
Turning
.
Nuclear Plant Dismantling
Materials
o
Steels
.
Non-ferrous alloys
"
Ti alloys, Ni- alloys
.
Polymers
'Honeycombs
.
Metal Matrix Composite
.
Ceramic Matrix Composite
e
Concrete
o
Stone
-
Granite
.
Wood
.
Reinforced plastics
o
Metal Polymer Laminates
.
Glass Fibre Metal Laminates
Tra.iectory of an
abrasive pariicle
lnieraciian wtth
fociissinc iui-re
Mixing chamber
Schemotic view of
mixing pracess
Focusslng tube
Schemqtic and
photographic
view af
the cutting head
,,
FtUh,piessur
'
r,ai*r
..
,:).ii:i..
<
-
+Ji t5i; ii
WaterJet
3/6/2014
The velocity of the water
jet
thus formed can be estimated
assuming no losses as
v*i= (Zp*
I
p)r/,
Mixing process may be mathematically moo",,uo as follovrs. Taking into aecount the
energy loss during water
jet
formation at the orifice, the vrater jet .relocity
nray be
given as,
.. _ rr/
I I
7t ,,
r!
= Velocity coefficientof the orifice
r
-
T i--------
',7
'1l
.r1
+=Coefficientof"vena-contractct,'
!
f i'
cd= Dischotge rcefficient of ihe orifice
4,,
:
t! X 1',.r :{ ,l,r1ric
I]
, :
'Ihe
volume flow rate o{ water
!"
-
('i
r
"
-,
"
may be expressed as:
.
II l, ,,,
4,, - d
"'
rl,- :<
t['
\l ,],t'
' Il . li,,
(l
,, =
(
, i.
'.
t/
,- '
.t
i...{.
"
-1
1*
/r,,
The total power of the water
jet
P,ti
l'tt,
x(ltt
Y. {:i Y
fI
t
""'
t;
t1 n.
ti-A
ti
=11
:11
-
i.
Momentum of the
jet
before and
after mixing is conserved.
i.,.1
]
"'r-
t'1..,
t
P
.l.)t)
1
1
-.'--
----1
.irri
I' r,i
i- rt ,
l?
= i*ading {actor
=
11
= momentum loss factor.
^
i'j
', t
-
l-l'll'
u x i-_
"
! lri,
i- -
--;-
t-t'11
v;,.
fI
;-
+
7
I
t
I
j...
'jrr.i, t_:.. l
t )r I
'i?ii:'l
316/2A14
Eypaes Principle
B'vpass trressure vfsse
kli8a IY*$r
Y
Scbematic af /1WJt\4
(Suspension
type)
l:tE-t:f
\
!ai ir3laihr pidtrjs i i!B
*.:
nerl.rabr
ftf,:
-/
./
./
,
,"'q--L
I
Gi
IB JF
-i_
i
:'
ll
Catcher
- ------'-lr
!i
i, i
'
i)
: !,'i
,,,
i
io i'i
N il.;
z t..l
Waterjet lag
lndilect Pumpin5l
hpr,. ale[
6
3/6/201,4
ir.
I ,r*ta,,,acr.,i
Mechanism of
.
zl.e
,r.*=-.
material removal
i\,
i
t'\
,'
i
: \
, I
schenotic of A'r\:Jrvt kerf
It1
\
r\t J
jii(
Ir
Striation
Photogrophic view oJ kerf
marks (longitudinalsection)
Mechanism of rnaterial removal
The general
domain of parameters
in entrained type
AWJ machining system is given
below:
.
Orifice
-
Sapphires
-
0.1to 0.3 mrn
n
Focussing Tube
-
WC
-
0.8 to 2.4 mm
.
Pressure
-
2500 to 4000 bar
.
Ahrasive
-
garnet and olivine - #125 to #60
.
Abrasive flow - 0.1to 1.0 Kglmin
.
Stand off distance
-
1 to 2 mm
.
Machine lmpact Angle
-
60o to 900
.
Traverse Speed
-
100 mm/min to 5 m/min
.
Depth of Cut
-
1 mm to 250 mm
3/612014
In water
jet
machining, the material removal rate may be assumed to be
proportional
to the
power
of the water jet.
The proportionality
constant L is
the speciffc energy requirement and would be a property
of the
yvork
material.
ii 'r,
- '!
I i' il
I /r
power
of the abrasive phase
of the abrasive urater jet
can be estimated as,
Thus it may be assumed that the material removat rate is proportional
to the power
of abrasive phase
of AWJ. The water phase
does not
contribute to material removal in AWJM.
-j
s
:ht
it
:: ;''.,,
';
t'
,,
-
,
,i
.
-
,i
.1rnR
D
MRR wvr
u
1ot=
speCiqc energy requirement in machining a material irr
AWJM
4=
depth of penetration
w
=
width of the kerf
=
(w
,oo
* w
,*,,,,,,,) /
2
x
d,
,
the diameter oF the focussing tube or nozzle or the insert
r,,= traverse speed of the AWJ or cutting speed
Therefore, r+ MRR: hrd,v,
Q
ir,=i
fi
nt
tt
+ '
"l
r-R
j
ll-'
:
tr..,il'-r',.
!
rr,,
l*T
ll
,,t^
,
-!i
. f
-1
''
f1 t
i--f.i
n
i'.,
rs tn? ioaCinil
ilarar.ielet
{ =
koefisien, yang memperhitungkan beber-apa faktor seperti ketajaman atau kusam
dari kerapuhan. aLrrasi[ stand-off distance, process inhr:niogenities etc
Opiimal loading r"atio is required to be deterrrinecl by
r.
differentiating with respect to the loading ratro, R
r:-
=f,..-..'--".-"_.------._
;! rri_
tl
-
ti I
h^
_iI-N,.4
,t l;
'=L,l-iir
--,t-
,l* Fr-
iir
i
-,R
: t-t
='
:Ll
3l6l2aM
t],25
lLZ
$.I5
0.1
0.0s
0
0.5 t,0 1"5 2.9 2.5 $.0
Voriotian in cutting obility of AWJM with mixing rotio
Problerns
1. Assuming no losses, determine water
jet
velocity, when
the water pressure is 4000 bat being issued from an
orifice of diameter 0.3 mm
2. Determine the mass flow rate of water for the given
problem assuming all related coefficients to be 1
3. If the mass flow rate of abrasive is 1 kg/min, determine
the abrasive water
jet
velocity assuming no loss durinq
mixing process using the above data (data of
Question.
1, 2 and 3)
4. Determine depth of penetration, if a steel plate is AWJ
machined at a traverse speed of 300 mm/min with an
insert diameter of 1 mm. The specific energy of steel is
13.6 J/mm3
"\-
\-l
*t\
\.
\
----\--
\-
,\
:i
-
* *
-t*
--
-
*
I
';
ti
* *
-: - - - -t- - - -
!!
1l
il
.---j i_***
ri
ri
ii
ri
tlr
tlr
t/i
lt
I
-l:*-
11
I
Ir
r
tt
I
ii
*.4--*
Ir
it
!!
i;
- -! -
* *
-,- - - -
!i
ri
tt
l!
-J---*l--.--
It
l!
II
,t
lt
I
a
I
i
i
t
t
i
i
e
t
;
i
I
T
t
t
I
I
I
t
I
t
i
!
316/2014
o,26
U
fi.2
s.1s
0"I
0.05
0
0.5 t.0 i"5 2.9 2.5 $.s
Variation in cutting obility of AWJM with mixing ratio
Problems
1. Assuming no losses, determine water
jet
velocify, when
the water pressure is 4000 bar, being issued from an
orifice of diameter 0.3 mm
2. Determine the mass flow rate of water for the given
problem assuming all related coefficients to be 1
3. If the mass flow rate of abrasive is 1 kg/min, determine
the abrasive water
jet
velocity assuming no loss durinq
mixing process using the above data (data of
Question.
1, 2 and 3)
4. Determine depth of penetration, if a steel plate is AWJ
machined at a traverse speed of 300 mm/min with an
insert diameter of 1 mm. The specific energy of steel is
13.6 J/mm3
{
I
I
i
I
I
I
;rl
llt
li
lll
l,i
{+.-*-i*-'.--+*,-
{'t
tit
iall
L
rli
-l
* *
-
*,-
-
i-
-
:r1
Ili)
tit
lltl
J----r----L
,!i
llt
tt,
ttt,
ltll