Water Jet Machining: Recent Development

Recent
development of
Water Jet
Machining
Reyad Mehfuz
1
Water Jet Machining- recent development
Overview
1. Introduction
2. General overviews
3. Recent developments
4. Conclusion
2
Introduction
 First water jet machining patented in 1960 by
Norman Franz
 First industrial application as a new cutting tool
in the early 1970
 Usually used to cut soft materials like paper,
food, plastics, cardboard, wood, leather
 Only very thin sheets of metals can be cut with
pure water jet.
 It is also not suitable for cutting glass or high
strength composites.
3
Introduction (Contd.)
 Removes material through the
erosion effects of a high velocity,
small diameter jet of water
 Sameprinciple of ‘rain-erosion
phenomenon’ occurring on high
speed aircrafts.
4
Introduction (Contd.)
Two steps of cutting:
2. High pressure pump or intensifier
pressurizes water to produce the energy
required for cutting.
3. Water is then focused through a small
precious stone orifice to form an intense
cutting stream.
5
Advantages
 Water is cheap, non-toxic, readily
available, and can be disposed easily.
 Any contour and sharp corners can be cut
cleanly. The operation is possible in both
horizontal and vertical positions.
 Absence of heat-affected zone.
6
Advantages (Contd.)
 Sticky materials can be smoothly cut
without causing any clogging.
 Dust- free process.
 Minimum kerf-width
 No contamination problem.
 Easy automation.
7
Mechanism
8
Process Parameters
 velocity of the jet or jet pressure
 stand-off-distance,
 nozzle diameter,
 traverse rate,
 feed rate and depth of cut, and
 the properties of the material being cut.
9
Effect of jet pressure
If
Jet Pressure
then
Depth of cut
MRR
10
Effect of stand-off
1
distance
2 1 reduction
 in
nozzle pressure
with decreasing
distance
2 a
 reduction in
the jet velocity
with increasing
distance
11
Effect of traverse rate
12
Effect of nozzle
diameter
10
9
8
7 Nozzle diameter
Depth of cut (mm)
6
5
0.08 mm Nozzle dia
4 0.1 mm
3
2
1
Depth of cut
0
0 200 400 600 800 1000
Pressure (MPa)
13
Recent
Development
14
High pressure water jet
15
High pressure water jet:
 Use of high pressure water jet (900MPa)

for machining sheet metal of different
materials, Al and Zn
 Fracture mechanism varies with the
material properties.
 Aluminium shows ductile fracture while
zinc shows brittle fracture.
Louis et al. (2003-04)

16
High pressure water jet

(contd.)
 high pressure water jet application using
smaller orifice have better power
efficiencies
 increases both maximum cutting speed
and depth of cut with the increase of
pressure.
Suzulu et al. (2004-05) 17

Nozzle shape
Specific waterjets
Rectangular consumption
are found by
moretheefficient
rectangular nozzle
for improving
was found
surface significantly
processing reduced and the productivity
techniques.
greater than that of the commercial round nozzles.
18
Nozzle materials
Parameters for nozzle materials wear
 water quality and chemistry,

 the operating pressure, and
 the nozzle design.
19
Nozzle materials (contd.)

Recommended Operating Conditions
Nozzle Material
Carbide • Dirty, unfiltered water; pressures below 140

MPa (20,000 psi)
Steel • Water filtered to 25 micron or better, pressures
below 140 MPa
Sapphire • Water filtered to 10 micron or better, pressures

above 140 MPa
Diamond nozzle shows better performance over sapphire

nozzle at high pressure in terms of jet stability. (Louis et al.)
20
Water jet-cleaning
nozzles
Nozzle types Performance
Basis Cone Jet Poor
•Erosion rate Fan Jet Good

•Erosion depth
Resonating jet Poor
Cavitating jet Better
21
Water jet forming

 Promising in the field of the rapid
prototyping and could be used to form
thin metal sheet without using dies in the
future.
 New applications of WJF process could be
forming processes to obtain wing shape of
aircraft or shape of some car body
components
22
Water jet peening

 WJP induces compressive residual
stresses that benefit the fatigue life of
materials
 Recent work shows more analytical
mathematical models on
– Prediction of residual stresses
– Prediction of feasible peening range
with different contact pressure
23
Water jet in mining

 High pressure pulsed
water jet to achieve
high energy
efficiency in coal
mining application
 Swing-oscillating jets
and the rotating jets
attain better
Fig . Dosco MK2B Roadheader efficiency
24
Water jet in packaging

industry
 For the processing of cardboard boxes and
foams.
Advantages over conventional processing:
•High production rate

•Cheaper
•Higher quality
•Contour and straight cutting of
thicker foams with high quality
25
WJ in packaging industry
(contd.)
26
Water jet in food

processing plants
 contamination free cutting of frozen fish,
meat, vegetables, chocolate bars and ice-
creams.
 High pressure pure water jet is also found
effective than conventional oscillating
blades in cutting sandwiches.
27
WJ in food processing plants

(contd.)
Relative comparison
28
Water jet guided LASER

technology
Application:
 wafer slicing
 Damage free dicing
Laser beam is conducted

to the work piece inside a
thin low-pressure water-
jet by total internal
reflection that takes place
at the water-air interface
29
WJ guided LASER technology

(contd.)
Advantages compared to conventional LBM:
 no contamination and thermal effect,

 damage free dicing,
 low laser divergence hence high efficiency
30
Temperature
distributions of WJ
 Temperature
distributions of
water jet using
infrared thermal
imager.
 Fluctuation of the
turbulence can also
be expressed in the
infrared thermal
images.
31
Medical applications
 High powered
parallel water jet
 Used in wound
debridement
 high precision and
accuracy
 Far better than
conventional
scalpel
Trade name: VersaJet

32
Other Recent
developments
 Underwater rock cutting by water jet
– most appropriate application of pure
water jets under the water level is
removing of the eroded brittle non-
homogeneous material.
33
Conclusion:
Three main areas of research:
1. The fragmentation of solids, e.g. mining and

hydrodemolition;
2. The separation of coatings from solids, e.g.
waterjet cleaning;
3. Precise cutting of solids, e.g. factory
applications and medical applications.
34
Conclusion (contd.)
 The historical trend of the advancement of
waterjet technology is toward more
precise control.
 Machining of high hardness and thicker
metals are still not found suitable by pure
WJM.
35
Thank you
Any Q ???
uery…
36

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Effect of jet pressure

Effect of traverse rate

High pressure water jet

High pressure water jet:

 Use of high pressure water jet (900MPa)

Louis et al. (2003-04)

High pressure water jet

Suzulu et al. (2004-05) 17

Parameters for nozzle materials wear

 water quality and chemistry,

Nozzle materials (contd.)

Carbide • Dirty, unfiltered water; pressures below 140

Sapphire • Water filtered to 10 micron or better, pressures

Diamond nozzle shows better performance over sapphire

Basis Cone Jet Poor

•Erosion rate Fan Jet Good

Cavitating jet Better

Water jet forming

Water jet peening

Water jet in mining

Water jet in packaging

Advantages over conventional processing:

•High production rate

Water jet in food

WJ in food processing plants

Water jet guided LASER

Laser beam is conducted

WJ guided LASER technology

 no contamination and thermal effect,

Trade name: VersaJet

Three main areas of research:

1. The fragmentation of solids, e.g. mining and

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