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PARAMETRIC ANALYSIS OF ABRASIVE WATER JET MACHINING

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 Vol-8 Issue-4 2022 IJARIIE-ISSN(O)-2395-4396

PARAMETRIC ANALYSIS OF
ABRASIVE WATER JET MACHINING
Shrirang chandrakant kanade, J.B.Sheikh
Dr. Babasaheb Ambedkar Technological University Lonere, Dist.- Raigad, Maharashtra, India
Department of Mechanical Engineering, Deogiri Institute of Engineering and Management Studies,
Aurangabad

ABSTRACT
The present research work highlights the simulation study of AWJM process parameters, i.e. velocity of jet, Jet
impingement angle, grain size and stand-off-distance on pressure, stress and Deformation generated at the jet
impact surface, erosion rate during the fabrication of micro holes generation. K -60 Ceramic is widely accepted
in the non-conventional machining process and associated industries with the years of track on record of proven
performance in a vast number of brittle materials. The intense hardness and high strength of sintered ceramics
creates it tough to machine them economically. The present surface development models are established for air
abrasive driven erosion progressions which cannot account for the result of heated abrasive movement on the
target channel sidewall erosion that indicates to the advanced channel broadening detected in the AWJM of
brittle materials. This paper focused on ideal numerical mo del to predict the surface contours of micro-holes in
brittle material as name K-60 ceramic using AWJM. Most perceptible act in this research is to the selection of
abrasive particle that for to achieve the appropriate intricate shaped holes upon K -60 ceramic with silicon
carbide abrasives. The exact erosion rates of this material, pressure, stress generation and deformation due to
stresses are measured.

Keywords, K-60 ceramic, 3-D CFD model, SiC abrasive, AWJM, ANSYS 18.1 CFX.

1. INTRODUCTION
ABRASIVE WATER JET MACHINING PROCESS

In our current research work we are focusing on Mechanical based Non -Traditional Manufacturing process, i.e.
Abrasive water jet manufacturing process. . In these processes higher kinetic energy of abrasive part icles jet and
water jet is employed for remov ing materials fro m the work piece. In ab rasive water jet machin ing process
material removal takes fro m the surface of work material because of the impact of high velocity and pressure of
water/abrasive jet on it and the energized particles generates stresses on it and due to stresses brittle fracture
forms at that surface and due to the subsequent impact of abrasive particles material removal occurs. The
schematic diagram of abrasive water jet machining is displayed below.

Fig.1. Schematic Diagram of AWJM machining process

2. BOUNDARY CONDITIONS USED FOR SIMULATION:

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pressure based system, steady state and incompressible flow condition with energy method, k-epsilon
turbulence model ,Discrete phase model (DPM ) and PISO scheme is used in ANSYS FLUENT 18.1 CFD tool
for inject ing the hot abrasive jet on to the work piece as per the design in Design modeler. Before in itializat ion
of flow and calculat ing the result in the solver unit the input flow parameter for the jet and the properties of
work p iece material and abrasive particles has been assigned at the cell zone condition as well as in boundary
condition which is shown in Table 6 for getting the simulation output responses.
Table 1: Flow, solver setting and model parameter

Flow and model parameter Value

Mass flow rate 0.01 kg/sec

Inlet velocity of jet 250 m/s, 280 m/s, 310 m/s, 340 m/s

Jet Impact Angle 65o C , 75o C, 90o C, 105o C

Abrasive particle diameter 245 µm , 445 µm, 645 µm, 845 µm

Stand-off distance 4 mm , 6 mm, 8 mm, 10 mm

Pressure velocity coupling PISO

Momentum 2nd Order

Turbulent kinetic energy 2nd Order

Turbulence dissipation rate 2nd Order

Skewness correction 0

Neighbor correction 3
Model Energy and DPM model
Turbulence model K –epsilon turbulence model

3. CFD MODELLING
Geometric modeling

Geo metric modeling is the introductory phase in CFD simu lation which develops the simulation flow field.
Often making the geometry a simpler one, trying to restrict the geometry to the field that includes flu id flow,
and avoiding the finer details in the layout. Intricate specifics make grid generation and simu lation difficult.
Novel design of Tungsten carbide (WC) nozzle with dimension and figure shown in Table 2.
Table 2: Geometric parameter of nozzle

Geometric parameter Dimension

Inlet diameter 10 mm

Outlet diameter 4 mm

Focus tube length 21 mm

Convergent angle 2090

Converging length 7.0 mm

Body length 20 mm

Total Nozzle Length 48 mm

K-60 Alumina ceramic work piece of size 40×40×2 is designed at a certain distance stand -off distance (from the

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exit surface of nozzle) along with frozen operation for maintain ing the gap between nozzle exit and work p iece
for making the nozzle and fro zen body in to a single body at desired plane using the suitable coordinate system
in design modeler

Discretization and Grid Generation

The methods to Discretization/meshing are used to transform a mathemat ical model into a discrete, algebraic
equation system. There are typically three types of methods that are used to discrete. Finite element method
(FEM) is used for stress analysis, but fluid flo ws use finite difference method (FDM) and finite volu me method
(FVM) is used for industrial CFD codes
Here the equation of mot ion of AWJM is solved by CFD tool ANSYS Fluent. The assembly of nozzle body and
the work piece is discretized in to 1 mm element size along with 87655 no of element of tetrahedral mesh after
the Boolean operation in Design modeler shown in Figure 02.

Fig.2: Discretization at different Impact angle

4. RESULT AND DISCUSSION

4.1 Effect of Velocity of Jet, Grain Size of Abrasive, Stand -Off-Distance, and Impact angle of Abrasive jet on
Pressure on the Impact Surface of Jet on the Work Piece:

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Taguchi is a strategy for defin ing and developing knowledge scientifically, so that it c an be used in a well
structured manner to improve the machining process. According to the definition, DOE can be applied to the
regions where it is necessary to acquire and apply the information efficiently and quickly in any field of
requirements. Here, Tab le 3 represents the Taguchi design matrix for simulat ion. According to this the
simulation result of pressure profile at the impact surface of work piece has been displayed below in Figure 3-4.

Table 3: Taguchi simulation matrix for simulated pressure value at target zone.
Grain
Run No Angle Velocity SOD Pressure (In Mpa)
Size
1 65 250 4 245 0.9321
2 65 280 6 445 0.9856
3 65 310 8 645 1.1065
4 65 340 10 845 1.3124
5 75 250 6 645 1.6321
6 75 280 4 845 1.5672
7 75 310 10 245 1.2654
8 75 340 8 445 1.789
9 90 250 8 845 1.923
10 90 280 10 645 1.2123
11 90 310 4 445 2.1126
12 90 340 6 245 2.0234
13 105 250 10 445 1.8753
14 105 280 8 245 1.7765
15 105 310 6 845 1.8623
16 105 340 4 645 2.0211

Fig.3 Velocity Profile and Contour at different Parameter

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Fig.4 Pressure Profile and Contour at different Parameter

4.2 Effect of Velocity of Jet, Grain Size of Abrasive, Stand -Off-Distance, and Temperature of Abrasive on
Deformat ion and Stress Generated on the Work p iece Due to the Impact of Jet. Simulat ion result for maximu m
stress profile at the target impact zone of jet and the deformation due to the stress generation has been
displayed below in Figure 5- 6.

Table 4: Taguchi simulation matrix for Stress and deformation at target zone

Stress Deformation
Run Grain
Angle Velocity SOD (MPa) (mm)
No Size

1.7345
1 65 250 4 245 0.8765

0.7745 1.5674
2 65 280 6 445

0.7323 1.3456
3 65 310 8 645

0.7156 1.2280
4 65 340 10 845

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0.9123 2.6543
5 75 250 6 645

0.9056 2.7654
6 75 280 4 845

0.8996 2.6243
7 75 310 10 245

0.8134 2.6432
8 75 340 8 445

1.1127 4.0947
9 90 250 8 845

0.9481 3.5315
10 90 280 10 645

1.2839 4.8157
11 90 310 4 445

1.1983 4.1736
12 90 340 6 245

13 105 250 10 445 1.0087 3.4543

0.9765 3.9191
14 105 280 8 245

0.9123 3.9765
15 105 310 6 845

0.8995 3.9982
16 105 340 4 645

Fig.5 Deformation Contour Profile different Parameter

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Fig.6 Stress Profile contour at different Parameter

4.3 Effect of Velocity of Jet, Grain Size of Abrasive, Stand-Off-Distance, and Impact angle of abrasive jet on
Erosion Rate at the Target Surface of the Work piece: Simulat ion result for erosion profile at the target impact
zone of jet on the work piece has been displayed below in Figure 7-12.

Table 5: Taguchi simulation matrix for simulated erosion rate at target zone.
Material
Run Grain Erosion
Angle Velocity SOD
No Size (Gram/m2 -sec)

0.000564
1 65 250 4 245

0.000431
2 65 280 6 445

0.000229
3 65 310 8 645

0.000193
4 65 340 10 845

0.000765
5 75 250 6 645

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0.000851
6 75 280 4 845

0.000721
7 75 310 10 245

0.000815
8 75 340 8 445

0.00291
9 90 250 8 845
0.00186
10 90 280 10 645

0.00386
11 90 310 4 445

0.00354
12 90 340 6 245
0.00107
13 105 250 10 445

0.00165
14 105 280 8 245
0.00267
15 105 310 6 845

0.00298
16 105 340 4 645

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Fig.7-12 Material Erosion Profile at different Parameter

5. CONCLUSION
The pressure at the impact zone of heated abrasive jet, erosion at the target impact zone of jet, erosion inside
the nozzle surface and deformation due to stress resulting fro m the simu lation of AWJM of K -60 ceramic using
SiC abrasive was performed. The results of simulat ion approach display minor variations if we co mpare the
responses, which are getting from simulation using SiC. The following points are determined in this research.

• Induced pressure at the impact zone of jet is directly p roportional to ve locity of jet, maximu m grain size of
abrasive, perpendicular jet imp ingement angle, i.e. By increasing the velocity of jet, and abrasive grain size
maximu m pressure is generated on the target zone but for getting maximu m pressure at that surface stand -off
distance should be small.
• Target material erosion per hot abrasive particle was shown proportional to the abrasive kinetic energy of
the particles with minimum stand- off distance in order to avoid the deep chipping formation on the target zone.

• In order to reduce the erosion inside the nozzle surface optimu m velocity of jet with moderate grain size o
of abrasive should be maintained for compensating the erosion rate at the target zone on the work piece.

• As we know that erosion takes places due to deformat ion of material, which is generated by stress. So stress
is direct ly proportional to the velocity of jet, perpendicular (900) with maximu m grain size of abrasive by
maintaining smaller stand-off-distance.

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