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Abrasive Water Jet Machining (AWJM)

Abrasive water jet cutting is an extended version of water jet cutting; in which the water jet contains abrasive particles such as silicon carbide or aluminium oxide in order to increase the material removal rate above that of water jet machining.

ABRASIVE WATER-JET MACHINING (AWJM)

 

3.1. Introduction

 

Abrasive water jet cutting is an extended version of water jet cutting; in which the water jet contains abrasive particles such as silicon carbide or aluminium oxide in order to increase the material removal rate above that of water jet machining. Almost a ny type of material ranging from hard brittle materials such as ceramics, metals and glass to extremely soft materials such as foam and rubbers can be cut by abrasive water jet cutting. The narrow cutting stream and computer controlled movement enables this process to produce parts accurately and efficiently. This machining process is especially ideal for cutting materials that cannot be cut by laser or thermal cut. Metallic, non-metallic and advanced composite materials of various thicknesses can be cut by this process. This process is particularly suitable for heat sensitive materials that cannot be machined by processes that produce heat while machining.

 

The schematic of abrasive water jet cutting is shown in Figure 15 which is similar to water jet cutting apart from some more features underneath the jewel; namely abrasive, guard and mixing tube. In this process, high velocity water exiting the jewel creates a vacuum which sucks abrasive from the abrasive line, which mixes with the water in the mixing tube to form a high velocity beam of abrasives.

 

3.2.Applications

 

Abrasive water jet cutting is highly used in aerospace, automotive and electronics industries. In aerospace industries, parts such as titanium bodies for military aircrafts, engine components (aluminium, titanium, and heat resistant alloys), aluminium body parts and interior cabin parts are made using abrasive water jet cutting.

In automotive industries, parts like interior trim (head liners, trunk liners, and door panels) and fiber glass body components and bumpers are made by this process. Similarly, in electronics industries, circuit boards and cable stripping are made by abrasive water jet cutting.

 

.3.4.Advantages of abrasive water jet cutting

 

               In most of the cases, no secondary finishing required

 

               No cutter induced distortion

 

               Low cutting forces on work pieces

 

               Limited tooling requirements

 

               Little to no cutting burr

 

               Typical finish 125-250 microns

 

               Smaller kerf size reduces material wastages

 

               No heat affected zone

 

               Localises structural changes

 

               No cutter induced metal contamination

 

               Eliminates thermal distortion

 

               No slag or cutting dross

 

               Precise, multi plane cutting of contours, shapes, and bevels of any angle.

 

3.5 Limitations of abrasive water jet cutting

 

               Cannot drill flat bottom

 

               Cannot cut materials that degrades quickly with moisture

 

               Surface finish degrades at higher cut speeds which are frequently used for rough cuts

 


 

The major disadvantage s of abrasive water jet cutting are high capital cost and high noise levels during operation.

 

A component cut by abrasive water jet cutting is shown in Figure .As it can be seen, large parts can but cut with very narrow kerfs which reduces ma terial wastages. The complex shape part made by abrasive water jet cutting

 

 

 

 

3.6. Abrasive water jet cutting

 

        WJM - Pure

 

        WJM - with stabilizer

 

        AWJM – entrained – three phase –abrasive, water and air

 

        AWJM – suspended – two phase –abrasive and water o direct pumping

 

i.  Indirect Pumping

ii. Bypass pumping

 


 

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