Seminar on WATERJET MACHINING

presented by S.Logeshwaran V.M.Mohammed Safiudeen III B.E Mechanical Engineering

Department of Mechanical Engineering, Coimbatore Institute of Engineering and Technology Coimbatore

Introduction to Water jet

It

is the fastest growing machining process. of the most versatile machining processes.

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Compliments

other technologies such as milling, laser, EDM, and plasma. cold cutting process No HAZ , mechanical stresses or operator and environmental hazards. limited to machining but also used in food industry applications.
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True

Not

Evolution of Waterjet :

1930s: Mining Industry to remove stones and coal 1960s : Need to cut advanced materials for aerospace industry 1970s : First attempts were to employ WaterJet to cut advanced composites for aerospace applications. 1980s: First commercial AWJ machines
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PRINCIPLE OF WORKING

Fig. Structure of a water jet machining.

TYPES OF WATER JET CUTTING

Water jet cut Abrasive jet cut Abrasive water suspension jets

Water jet :
jets are used for cutting soft materials Jet Machinable Materials

Water

Water Like

Soft rubber, foam, tin foil, carpet, soft gasket material

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Abrasive water jet

Abrasive An

water jets for hard materials

abrasive element is added to the water beam to assist cutting

Abrasive Water

Jet Machinable materials: Titanium, aluminum, stone, hard rubber, hardened tool steel

Components
Pump
Nozzle Orifice Control

System
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Components Pump :
50

100 hp electric driven pump Hydraulic Based Operation Pressures Up to 60,000psi (4000 bar) Output
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Smooth

Components Nozzle:

Components Orifice:

Orifices 0.25 -- 0.75mm

Garnet Abrasive Particles

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Components Control System

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Materials:
The

list of materials that a Water jet system could penetrate is significant. To date, Applications have been used with:
Ceramic Tile, Wood , Rubber, Glass, Marble and Granite ,Foam , GIO Phenolic , Steel, Armor plating ,Urethane, Titanium , Kevlar, Aluminum , Brass , Copper, Stainless Steel , Spectra, Fiberglass , Corrugated Cardboard , Acrylic .

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Surface Characteristics Variables of Cuts

Water jet Pressure

Water jet Diameter

Abrasive Material Type

Abrasive Material Size

Abrasive Material Flow Rate

Traverse Speed
The Cutting Angle
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Advantages:

No heat affected zone Stress-free cutting No residual stresses Wide range of materials Environmentally friendly No need for surface finish No tool changing Minimal Fixturing Required
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Cont. Advantages:
Faster than

any other technique

Saves Raw Material

Flexible Machining Integration

Does Not Need a Starting Hole Ability to Cut in Any Direction
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Disadvantages:
Limited

number of materials can be cut economically Very thick parts can not be cut with Water Jet

Cutting

and still hold dimensional accuracy

Slower cutting rate compared to both plasma and oxyfuel cutting processes Higher entry cost
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Comparison to other Methods

WaterJet v/s Wire EDM
Can

Cut through any material No Need for a Starting Hole No Heat Affected Zone

Limited

to Conducting Materials A Starting Hole is Needed for the Wire

Heat Affected Zone

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WaterJet

v/s

Laser
Minimal Heat Affected Zone

No Heat Affected Zone

Can Cut Through Reflective Materials

Can Cut Uneven Surfaces Smoothly Environmentally friendly Can Cut Up to 12 in hard materials (Ti, SS)& 24 in Rubber

Reflects on Shiny Surfaces

Laser Defracts and Looses its Focus

Produces Toxic Fumes

Max. Depth 0.5 0.75

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WaterJet

v/s Milling

Excellent Use of Raw Material No Tool Changing No Fixturing Required No Cleanup is Required

Large Amounts of Waste of Raw Material Frequent Tool Changing Fixturing is essential Requires Periodical Cleanup

Faster
No HAZ

Slow
HAZ

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Deciding which metal Cutting System is Best?

Variables to be considered when making a decision on the right cutting system to use :
Cutting

speed Edge cleanliness Degree of tolerance required Number and types of metal to be cut Capital investment Operating costs Size of heat affected zone Access to secondary machining processes
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Applications

Aerospace

Food Processing

Marble Industry

Automotive

Electronics and PCBs

Concrete
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Applications
Polymers and Composites

Steels With Different Thickness

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Applications
Ceramic part cut with an abrasive water jet

Steel gear and rack cut with an abrasive water jet

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Conclusion:

It is relatively a new technology which has caught on quickly and is replacing century-old methods used for manufacturing Used not only in typical machining applications, but food and soft-goods industries As material and pump technology advances faster cutting rates, longer component life and tighter tolerances will be achievable Paves the way for new machining processes that embrace simplicity and have a small environmental impact
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References:
Modern Machining Processes by P.C.Pandey & H.S Shan www.flowcorp.com www.waterjets.org www.aqua-dynamics.co.uk

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