DEPARTMENT OF MECHANICAL

ENGINEERING
RIT KOTTAYAM
THERMAL EFFECT ON ABRASIVE
WATER JET MACHINING
PRESENTED BY : GUIDED BY :
NANDAGOPAN G RAMESHKRISHNAN S
S7 (KTE21ME041) PROFESSOR OF
MECHANICAL DEPARTMENT MECHANICAL DEPARTMENT
 Thermal effect on

CONTEN
AWJM

T
1. OBJECTIVES
2. INTRODUCTION
3. ABRASIVE WATER JET MACHINING
4. SET UP
5. CASE STUDY
6. EXPERIMENTAL SET UP
7. RESULT AND DISCUSSION
8. CONCLUSIONS
9. REFERENCE
Dept. of Mechanical 2/2 RIT
Objective Thermal effect on
s AWJM

OBJECTIVE
S
1. To brief on the text book definition, process and set

up of AWJM.

2. To carry out temperature measurement at jet

impact zone.

3. To verify the thermal effects due to AWJM process.

Dept. of Mechanical 3/2 RIT

Introduction Thermal effect on
AWJM

INTRODUCTIO
N ABRASIVE WATER JET
MACHINING

• Non-conventional process.

• Use high velocity water mixed with abrasives.

• Cold working process.

• No thermal and mechanical distortion.

• Good finishing an accuracy.

Dept. of Mechanical 4/2 RIT

Introduction Thermal effect on

SET UP AWJM

• Hydraulic unit- Pump +Valve.

• Intensifier-Amplification of energy.

• Attenuator-Damps pressure fluctuations.

• Cutting Head-Convert pressurized water

to cutting tool

• Abrasive supply tank-Store abrasive

particle.
Courtesy Fig.
[5] 1 • Catcher-Energy absorbing bed.
Dept. of Mechanical 5/2 RIT
Case Study:Experimental Set Thermal effect on
up AWJM
CASE
EXPERIMENTAL SET UP STUDY
MATERIAL USED

• S235JR carbon steel.

• Carbon content of 0.19%.
• Chemical composition was confirmed by Energy Dispersive
Spectroscopy (EDS).
AWJM EQUIPMENT AND PARAMETERS

• PTV WJ1020-1Z-EKO abrasive water jet machine.

Fig. Courtesy
2 [4]
Dept. of Mechanical 6/2 RIT
Case Study:Experimental Set Thermal effect on
up AWJM
Variables Value

Pump pressure 380 MPa

Nozzle orifice diameter 0.25mm

Mixing tube diameter 1.02mm

Mixing tube length 76mm

Abrasive mass flow rate 250 g/min

Abrasive type Australian garnet #80

Standoff distance 2mm

Cutting speed 50 mm/min Courtesy

[1]
Dept. of Mechanical 7/2 RIT
Case Study:Experimental Set Thermal effect on
up AWJM
SPECIMEN PREPARATION

• Holes of varying depths (4 to 6 mm) to accommodate thermocouples.

• Thermocouples placed at different distances from the cut edge to monitor temperature
variations.

BLACK - SPECIMEN AREA

RED - POINT OF STRUCTURAL
ANALYSIS

Fig. Courtesy
3 [1]
Dept. of Mechanical 8/2 RIT
Case Study:Experimental Set Thermal effect on
up AWJM

TEMPERATURE MEASUREMENT INSTRUMENTS

[Link] imaging camera

• FLIR Systems Therma CAM SC640 thermal imaging camera.
• Temperature range from −40 to +1500 °C.
• Thermal sensitivity of 30 mK at 30 °C.
• The accuracy of temperature measurements was limited.
Fig.
4
2. Courtesy
Thermocouples [6]
• NiCr-NiAl type thermocouples.
• Withstand temperatures up to 1200 °C.
• Placed at varying depths within the specimen to capture temperature
gradients.
• More precise temperature measurements.
Dept. of Mechanical 9/2 RIT
Case Study:Experimental Set Thermal effect on
up AWJM
MICROSTRUCTURAL ANALYSIS

[Link] Tomography (CT)

• Nikon M2LES System.

• Determine the precise location of thermocouples.

• Assess the structural integrity of the material after cutting.

2. Optical
Microscopy
• Nikon Eclipse MA200 optical microscope.

• Analyze the morphology and grain structure of the

material.

• Detailed examination of the microstructural changes. Fig. Courtesy

5 [7]
Dept. of Mechanical 10/2 RIT
Case Study:Experimental Set Thermal effect on
up AWJM
3. X-ray Diffraction (XRD) Analysis

• Bruker D8 Discover Plus system.

• Identify the phase composition.

• Focusing on the presence of austenite.

Fig. Courtesy
4. Nanohardness 6 [8]
Testing

• Anton Paar micro combi tester (MCT)

• Measure material's hardness at a microscopic

scale
Fig. Courtesy
• Provide insight of effect on mechanical property.
7 [9]
Dept. of Mechanical 11/2 RIT
Case Study:Experimental Set Thermal effect on
up AWJM
PARAMETERS INVESTIGATED

[Link] Temperature

• The temperature generated in the cutting zone.

• Potential to induce phase changes in the material.

2. Material
Microstructure
• Impact of cutting temperature on the microstructure.
• Formation of new phases was closely monitored.

3. Surface
Integrity
• The quality of the cut surface.
• Effects of thermal energy on surface morphology and hardness.

Dept. of Mechanical 12/2 RIT

Case Study:Results and Thermal effect on
Discussions AWJM
RESULTS AND DISCUSSIONS

THERMOCOUPLE

• 5 holes with a diameter of 0.65

mm.

• Depths of 4, 4.5, 5, 5.5, and 6

mm.

• Software used to register the

temperature.

• The sampling time - 0.05 s.

Fig. Courtesy
• Accuracy - 0.1°C.
8 [1]
Dept. of Mechanical 13/2 RIT
Case Study:Results and Thermal effect on
Discussions AWJM

Fig. Courtesy
9
• Temperature vs Distance graph [1]
plotted from the result.
• Maximum temperature registered 67.2°C.
• Thermal capacity or heat transfer coefficient - heat convection
in all directions - thermocouple readings ineffective.

Dept. of Mechanical 14/2 RIT

Case Study:Results and Thermal effect on
Discussions AWJM
THERMAL IMAGING

• Aimed to compare the temperature difference between jet impact zone and base

metal.

• Readings did not exceed 30°C.

• Water jet masked the view of camera from taking exact measurement.

• Thermal imaging camera readings thus in effective as well.

X-RAY DIFFRACTION ANALYSIS

• XRD analysis conducted along the edge and in the base metal zone.

• Generally used to determne changes in the crystallographic lattice, size of the crystallites, etc.

• Diffraction patterns obtained - quantitative analysis - identify phases present.

Dept. of Mechanical 15/2 RIT

Case Study:Results and Thermal effect on
Discussions AWJM

• Only the Fe-α (ferrite) phase is reported.

Fig. Courtesy [1]

10

• Fe-α phase and Fe-γ (austenite) phase are

reported.

• Eutectoid transformation - minimum 727°C.

• Peaks of austenite - lower than ferrite peaks but

Fig. Courtesy
11 [1] higher than the background.
Dept. of Mechanical 16/2 RIT
Case Study:Results and Thermal effect on
Discussions AWJM
OPTICAL MICROSCOPY

Grain size

Fig. Courtesy Fig. Courtesy

12 [1] 13 [1]
• Comparative view of the microstructure.

• Near the cutting edge - fine-grained microstructure.

• Fine-grained zone extends up to about 40 µm.

Dept. of Mechanical 17/2 RIT

Case Study:Results and Thermal effect on
Discussions AWJM
Polygonization

Fig. Courtesy Fig. Courtesy

14 [1] 15 [1]

• Polygonization - dislocations within the grains rearrange themselves into subgrain boundaries.

• Edge showing more pronounced polygonization.

• Localized heating and plastic deformation.

Dept. of Mechanical 18/2 RIT

Case Study:Results and Thermal effect on
Discussions AWJM

Recrystallization

• Recrystallization - replace deformed grains

with new grains.

• Most evident in areas are close to the

cutting edge.

• Temperature and deformation are the most

intense.
Fig. Courtesy
16 [1]

Dept. of Mechanical 19/2 RIT

Case Study:Results and Thermal effect on
Discussions AWJM
Nanohardness

• Determine the effect of cutting

temperature.

• Specimen undergone polishing and

etching.

• Five measurements taken at load of 10

mN.

• Red colour dots - Nanointendations.

Fig. Courtesy
17 [1]
Dept. of Mechanical 20/2 RIT
Case Study:Results and Thermal effect on
Discussions AWJM

• Light area indicate austenite - hardness higher than base metal.

• Hardness in jet impact zone - 620.1 ± 12.2 HV.

• Hardness in base metal - 423.9 ± 14.5 HV.

• Change in hardness suggest plastic deformation.

• Hence eutectoid transformation confirmed.

Dept. of Mechanical 21/2 RIT

Conclusion Thermal effect on
s AWJM
CONCLUSIONS

• According to text book definition, AWJM is a non-conventional machining using water

jet along with abrasives.

• It is said to be a cold working process with no thermal distortions at all.

• The case study has proven AWJM is not completely free from thermal effects.

• XRD analysis has proved the local increase in the temperature above eutectic

temperature at jet impact zone.

• Optical microscopy allowed observation and confirmation of change in grain structure,

polygonization, recrystallization, and increase in hardness up to 150nm from

Dept. of Mechanical 22/2 RIT
cutting edge.
Reference Thermal effect on
s AWJM

REFERENCES

[1]. Damian Ba´nkowski, Piotr Młynarczyk and Irena M. Hlaváˇcová “ Temperature

Measurement during Abrasive Water Jet Machining (AWJM) “ , October 2022.

[2]. A. Anu Kuttan, R. Rajesh, M. Dev Anand, “ Abrasive water jet machining techniques and
parameters: a state of the art, open issue challenges and research directions “ , February 2021

[3]. Sławomir Spadło, Damian Ba´nkowski, Piotr Młynarczyk and Irena M. Hlaváˇcová, “
Influence of Local Temperature Changes on the Material Microstructure in AbrasiveWater Jet
Machining (AWJM) “ September 2021

Dept. of Mechanical 23/2 RIT

Reference Thermal effect on
s AWJM
[4]. Abrasive water jet machining machine ([Link]).

[5]. Set up of AWJM from Advanced manufacturing engineering, Pentagon Educational

Services.
.
[6]. FLIR Systems Therma CAM SC640 ([Link]

[7]. Nikon Eclipse MA200 optical microscope

([Link]
inverted-eclipse-ma200/)

[8]. Bruker D8 Discover Plus system

([Link]
x-ray-diffractometers/d8-discover-family/[Link])

[9]. Anton Paar micro combi tester (MCT) ([Link]-

Dept. of Mechanical 24/2 RIT
 THANK YOU
F O R Y O U R AT T E N T I O N

Dept. of Mechanical 25/2 RIT