BY CHANNAVEERAYYA MATHPATI

CONTENTS
Introduction

AWJM Machine Mixing Suspension jet Catcher Mechanism of material removal Specifications of different water jet cutting machines Applications Environmental issues and future Advantages of AWJM Conclusion References

INTRODUCTION

Water Jet Machining (WJM) and Abrasive Water Jet Machining (AWJM) are two non-traditional or non-conventional machining processes. They belong to mechanical group of nonconventional processes like Ultrasonic Machining (USM) and Abrasive Jet Machining (AJM). In these processes (WJM and AJWM), the mechanical energy of water and abrasive phases are used to achieve material removal or machining

MACHINE

1. LP Booster 2. Hydraulic drive 3. Additive mixer 4. Direction control 5. Intensifier 5A.LP Intensifier 5B.HP Intensifier 6. Accumulator

5B 5A 5

1, 2

Intensifier

Schematic and photographic view of the cutting head

MIXING
WATER JET TRAJECTORY OF ABRASIVE PARTICLE MIXING CHAMBER INTERACTION WITH FOCUSING TUBE

FOCUSING TUBE

Schematic view of mixing process

SUSPENSION JET
hp water from pump Restriction valve Pressure vessel By pass

Pressure valve

Abrasive

Suspension

Hp water from pump

Schematic of AWJM (Suspension type)

CATCHER

(a) water basin

(b) steel/WC/ceramic balls

(c) catcher plates

some typical catchers

MECHANISM OF MATERIAL REMOVAL

bt

burr

bb
Photographic view of kerf (longitudinal section)

Schematic of AWJM kerf

C u T T I N G A B I L I T Y

Mixing Ratio R Variation in cutting ability of AWJM with mixing ratio

PARAMETERS AFFECTING CUTTING PERFORAMANCE OF THE AWJM

Waterjet nozzle diameter. Supply pressure. Abrasive parameters. Abrasive material. Stand off distance. Impingement angle. Depth of cut.

Specification of different water jet cutting machines

Abrasive garnet water jet cutting for High Performance US$195/ton Abrasive Garnet for FOB China Waterjet Cutters US$295/ton > 95% purity, FOB Los Angeles hardness > 7.0 20 ton (44,000 pound) minimum order High Pressure Waterjet Pump Sub-System 55kpsi, 50HP 37kw, 3 phase 3.2L/min (0.9Gal/min) flow rate Starting at US$19,500

High pressure water jet pump

Water jet intensifier pump Fully assembled cutting head Fully Assembled Cutting Head with on/off valve

Starting at US$8,500 Starting at US$800

Water intensifier promotion parts

High pressure waterjet On sale now intensifer parts: ceramic plungers high/low pressure cylinders high/low pressure seal kit End bell check valve Assembly Hydraulic Piston manifold shift valve

APPLICATIONS

Paint removal Cleaning Cutting soft materials Cutting frozen meat Textile, leather industry Peening Pocket milling Drilling turning

Endless Possibilities
Unmatched versatility Expanded Capabilities Reduction in material and Production Cost Compliments Existing Technologies

Stainless steel plate (50 mm thick) machined with AWJ

Different engineering components machined with AWJ

Different engineering components machined with AWJ

Environmental issues and future

water recycling spent water disposal chip recovery abrasive recovery and reuse

Advantages

AWJM process maintains tight tolerances and produces parts quickly. AWJM produces no heat affected zone. Clean edges are produce. Up to 40 plies can be cut. Computer controlled. Generates no dust.

Limitations

Abrasives cannot be reused. Slight moisture pick up can takes place. Material removal rate is very low

Conclusion

The industry enjoys a reduction in replacement tooling costs, because more precision cutting is shifted to the water jet and less is being cut with the carbide cutting tools, the tooling experiences less wear. Water jets are suitable for cutting high-strength materials into intricate shapes because relatively high cutting rates can be achieved. The same water jet tool can be used on a variety of these materials simply by changing the cutting rate. Thus this process can be widely used for fabrication of a large variety of components cost effectively and efficiently.

References
[1].

Modern Machining Processes by PANDEY and SHAN, TATA McGraw Hill 2000 [2]. Elements of Workshop Technology vol.2: Machine tools by S. K. HAJRA CHOUDHARY,A. K. HAJRA CHOUDHARY, NIRJHAR ROY, Media Promoters and Publishers. [3]. www.howstuffworks.com [4]. www.thefabricator.com [5]. www.thomasnet.com [6]. www.omax.com