Skip to main content

Advertisement

SpringerLink
Log in

An Experimental Investigation on Machining of Hardened AISI 440C Stainless Steel Using Abrasive Water Jet Machining Process

  • Technical Article
  • Published:
Journal of Materials Engineering and Performance Aims and scope Submit manuscript

Abstract

The present study attempts to analyze the impact of abrasive water jet machining (AWJM) process parameters on surface roughness and kerf taper properties of hardened AISI 440C stainless steel. Considering process parameters such as jet-water pressure, nozzle traverse rate, and stand-off height, the experiments are planned using the central composite design (CCD) of response surface methodology (RSM). Analysis of variance (ANOVA) is applied to the experimental data to determine which process parameters significantly affecting the surface roughness (Ra) and kerf taper properties. It is observed that surface roughness and kerf taper are significantly affected by all the three mentioned process parameters. Surface roughness decreases by increasing jet-water pressure. Ra decreases with a decrease in stand-off height and nozzle traverse rate. Kerf taper decreases by increasing jet-water pressure. After that, it decreases as the nozzle traverse rate and stand-off height decrease. Both coded and uncoded responses are incorporated into the developed predictive model. The study finds that the model's predicted values agree with the observed data. The next step involves optimization, i.e., adjusting the process's variables until the surface roughness and kerf taper are minimized. Furthermore, the machined surface of the work material was carefully analyzed under the optical microscope to give preliminary insight into the surface profile and waviness. The erosion made by abrasive particles is visible. To gain further insight into the machined surface characteristics, it was further observed using microscopic at 100× magnification. The machined samples were then scanned using scanning electron microscopy (SEM) for microstructural study and analysis.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20

Similar content being viewed by others

References

  1. R. Suresh, S. Basavarajappa, V.N. Gaitonde, G.L. Samuel, and J.P. Davim, State-of-the-Art Research in Machinability of Hardened Steels, Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., 2013, 227(2), p 191–209

    Article  CAS  Google Scholar 

  2. S. Salleh et al., Carbide Formation During Precipitation Hardening of SS440C Steel, Eur. J. Sci. Res., 2009, 34(1), p 83–91

    Google Scholar 

  3. L. Pan, C. Kwok, and K. Lo, Friction-Stir Processing of AISI 440C High-Carbon Martensitic Stainless Steel for Improving Hardness and Corrosion Resistance, J. Mater. Process. Technol., 2020, 277, 116448.

    Article  CAS  Google Scholar 

  4. P.K. Samal, J.C. Valko, and J.D. Pannell, Processing and Properties of PM 440C Stainless Steel, Adv. Powder Metall. Part. Mater., 2009, 7, p 112–121

    Google Scholar 

  5. S. Thamizhmanii and S. Hasan, Relationship between flank wear and cutting force on the machining of hard martensitic stainless steel by super hard tools. In Proceedings of the World Congress on Engineering. 2010

  6. C.S.-S. Bars, Shapes: ASTM A 276. Grade MT. 304

  7. S. Thamizhmanii and S. Hasan, Machinability of hard martensitic stainless steel and hard alloy steel by CBN and PCBN tools by turning process. in Proceedings of the world congress on engineering (2011).

  8. M. Albertini et al., Comparative study on AISI 440 and AISI 420B stainless steel for dental drill performance, Mater. Lett., 2012, 79, p 163–165

    Article  CAS  Google Scholar 

  9. W. Grzesik, Machining of hard materials. In: Machining: Fundamentals and Recent Advances. Springer, London (2008)

  10. M. Shukla, Abrasive Water Jet Milling. In: Davim, J. (eds) Nontraditional Machining Processes. Springer, London (2013)

  11. V. Jain, Advanced (Non-traditional) Machining Processes. In: Machining: Fundamentals and Recent Advances. Springer, London (2008)

  12. R. Kovacevic, R. Mohan, and Y. Zhang, Cutting force dynamics as a tool for surface profile monitoring in AWJ (1995)

  13. Z. Liao et al., Dual-Processing by Abrasive Waterjet Machining—A Method for Machining and Surface Modification of Nickel-Based Superalloy, J. Mater. Process. Technol., 2020, 285, p 116768

    Article  CAS  Google Scholar 

  14. D. Arola and M. Ramulu, Material Removal in Abrasive Waterjet Machining of Metals Surface Integrity and Texture, Wear, 1997, 210(1–2), p 50–58

    Article  CAS  Google Scholar 

  15. H. Meng and K. Ludema, Wear Models and Predictive Equations: Their Form and Content, Wear, 1995, 181, p 443–457

    Article  Google Scholar 

  16. M. Hashish, Visualization of the Abrasive-Waterjet Cutting Process, Exp. Mech., 1988, 28(2), p 159–169

    Article  Google Scholar 

  17. I. Hutchings, Mechanisms of the erosion of metals by solid particles. 1979: ASTM International

  18. A. Momber and R. Kovacevic, Principles of Abrasive Water Jet Machining, Springer, New York, 1999.

    Google Scholar 

  19. J. Bitter, A Study of Erosion Phenomena Part I, Wear, 1963, 6(1), p 5–21

    Article  Google Scholar 

  20. J. Bitter, A Study of Erosion Phenomena: Part II, Wear, 1963, 6(3), p 169–190

    Article  Google Scholar 

  21. G. Sheldon and I. Finnie, The mechanism of material removal in the erosive cutting of brittle materials. 1966

  22. C.L. Che, et al., Study of abrasive water jet polishing technology. In Key Engineering Materials. 2011. Trans Tech Publ

  23. N. Yuvaraj and M. PradeepKumar, Study and Evaluation of Abrasive Water Jet Cutting Performance on AA5083-H32 Aluminum Alloy by Varying the Jet Impingement Angles with Different Abrasive Mesh Sizes, Mach. Sci. Technol., 2017, 21(3), p 385–415

    Article  CAS  Google Scholar 

  24. J. Vasek, P. Martinec, and J. Foldyna, Influence of properties of garnet on AWJ Cutting Process. In: M. Hashish (ed), 1993 Proc. 7th American Water Jet Conference, Vol. 1, Water Jet Technology Association, St. Louis, pp 365–387

  25. Y.F. Wang and Z.G. Yang, Finite Element Model of Erosive Wear on Ductile and Brittle Materials, Wear, 2008, 265(5–6), p 871–878

    Article  CAS  Google Scholar 

  26. M.K. Babu and O. Chetty, A Study on the Use of Single Mesh Size Abrasives in Abrasive Waterjet Machining, Int. J. Adv. Manuf. Technol., 2006, 29(5), p 532–540

    Article  Google Scholar 

  27. A. Hascalik, U. Çaydaş, and H. Gürün, Effect of Traverse Speed on Abrasive Waterjet Machining of Ti–6Al–4V Alloy, Mater. Des., 2007, 28(6), p 1953–1957

    Article  CAS  Google Scholar 

  28. J. Kechagias, G. Petropoulos, and N. Vaxevanidis, Application of Taguchi Design for Quality Characterization of Abrasive Water Jet Machining of TRIP Sheet Steels, Int. J. Adv. Manuf. Technol., 2012, 62(5), p 635–643

    Article  Google Scholar 

  29. M. Chithirai Pon Selvan, N. Mohana Sundara Raju, and H. Sachidananda, Effects of Process Parameters on Surface Roughness in Abrasive Waterjet Cutting of Aluminium, Front. Mech. Eng., 2012, 7(4), p 439–444

    Article  Google Scholar 

  30. V. Jain and P. Tandon, Effect of Slurry Temperature on Kerf Taper Angle in Abrasive Water Jet Machining. In 2nd International Conference on Innovations in Engineering and Technology (ICCET’2014) Sept. 19–20, 2014 Penang (Malaysia)

  31. M. Naresh Babu and N. Muthukrishnan, Investigation on Surface Roughness in Abrasive Water-Jet Machining by the Response Surface Method, Mater. Manuf. Process., 2014, 29(11–12), p 1422–1428

    Article  CAS  Google Scholar 

  32. P. Trivedi, A. Dhanawade, and S. Kumar, An Experimental Investigation on Cutting Performance of Abrasive Water Jet Machining of Austenite Steel (AISI 316L), Adv. Mater. Process. Technol., 2015, 1(3–4), p 263–274

    Google Scholar 

  33. P. Janković, et al. Aspects of Machining Parameter Effect on Cut Quality in Abrasive Water Jet Cutting. in Applied Mechanics and Materials. 2015. Trans Tech Publ

  34. P. Löschner, K. Jarosz, and P. Niesłony, Investigation of the Effect of Cutting Speed on Surface Quality in Abrasive Water Jet Cutting of 316L Stainless Steel, Procedia Eng., 2016, 149, p 276–282

    Article  Google Scholar 

  35. P.A. Dumbhare et al., Modelling and Multi-objective Optimization of Surface Roughness and Kerf Taper Angle in Abrasive Water Jet Machining of Steel, J. Braz. Soc. Mech. Sci. Eng., 2018, 40(5), p 1–13

    Article  CAS  Google Scholar 

  36. M. Kulisz, I. Zagórski, and J. Korpysa, The Effect of Abrasive Waterjet Machining Parameters on the Condition of Al-Si Alloy, Materials, 2020, 13(14), p 3122

    Article  CAS  Google Scholar 

  37. S. Wang, D. Hu, F. Yang, and P. Lin, Investigation on Kerf Taper in Abrasive Waterjet Machining of Aluminium Alloy 6061–T6, J. Mater. Res. Technol., 2021, 15, p 427–433

    Article  Google Scholar 

  38. P. Garikipati and K. Balamurugan, Abrasive Water Jet Machining Studies on AlSi 7+ 63% SiC Hybrid Composite, Advances in Industrial Automation and Smart Manufacturing. Springer, 2021, p 743–751

    Chapter  Google Scholar 

  39. H.Y. Ting et al., Prediction of Surface Roughness of Titanium Alloy in Abrasive Waterjet Machining Process, Int. J. Interact. Des. Manuf. (IJIDeM), 2022, 16(1), p 281–289

    Article  Google Scholar 

  40. V. Sisodia and S. Kumar, Experimental Study of Single Point Incremental Forming with Dummy Sheet, Int. J. Mater. Eng. Innov., 2019, 10(1), p 60–82

    Article  CAS  Google Scholar 

  41. V. Sisodia and S. Kumar, Study of AA-1050 Sheet Metal Parts Processed by Single Point Incremental Forming with Dummy Sheet, Int. J. Mater. Eng. Innov., 2020, 11(2), p 105–126

    Article  CAS  Google Scholar 

  42. R. Quiza and J. Davim, Computational Methods and Optimization. In: Davim, J. (eds) Machining of Hard Materials (2011). Springer, London

  43. H. Orbanic and M. Junkar, Analysis of Striation Formation Mechanism in Abrasive Water Jet Cutting, Wear, 2008, 265(5–6), p 821–830

    Article  CAS  Google Scholar 

  44. L.M. Hlaváč et al., The Model of Product Distortion in AWJ Cutting, Int. J. Adv. Manuf. Technol., 2012, 62(1), p 157–166

    Article  Google Scholar 

  45. A.I. Khuri, Response Surface Methodology and Related Topics, World Scientific (2006)

Download references

Author information

Authors and Affiliations

  1. Department of Manufacturing Engineering and Industrial Management, College of Engineering Pune, Pune, Maharashtra, India

    Vikas Sisodia

  2. Directorate General of Foreign Trade, Ministry of Commerce and Industry, Govt. of India, New Delhi, India

    Sahil Kumar Gupta

  3. Department of Mechanical Engineering, Vel Tech Rangarajan Dr Sagunthala R&D Institute of Science and Technology, Chennai, Tamilnadu, 600062, India

    Sachin Salunkhe & Arun Prasad Murali

  4. Department of Mechanical Engineering, Sardar Vallabhbhai National Institute of Technology, Surat, 395007, India

    Shailendra Kumar

Authors
  1. Vikas Sisodia
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Sahil Kumar Gupta
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Sachin Salunkhe
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Arun Prasad Murali
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Shailendra Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Sachin Salunkhe.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sisodia, V., Gupta, S.K., Salunkhe, S. et al. An Experimental Investigation on Machining of Hardened AISI 440C Stainless Steel Using Abrasive Water Jet Machining Process. J. of Materi Eng and Perform 33, 961–977 (2024). https://doi.org/10.1007/s11665-023-08040-y

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11665-023-08040-y

Keywords

Search

Navigation