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Experimental investigations on depth of penetration and surface integrity in AZ91/Al2O3 nano-composites cut by abrasive water jet

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Abstract

In the present study, an experimental investigation is conducted to determine the effect of process parameters on the depth of penetration and surface integrity in AZ91-metal matrix composite containing 1, 1.5, and 2 wt% of Al2O3 nano-particles through abrasive water jet cutting. Mixed level L18 orthogonal array is employed to conduct linear cutting experiments for both base alloy and nano-composites. Stir casting method is used to produce metal matrix nano-composites. The micro-mechanisms involved in material removal process are analyzed using SEM. Surface integrity of cut surfaces has been characterized using surface topography and 2D roughness profile observations. Water pressure and traverse speed are found to be the most significant factors in deciding depth of penetration. Penetration ability of nano-composites is decreased with increase in wt% of nano-Al2O3 particles. Two cutting regime, i.e., cutting wear and deformation wear, are observed from the SEM analysis and these mechanisms are found similar to the material removal mechanism in Mg alloys and other ductile materials. Contribution of high speed water jet to material removal process is also discussed. Embedment of sharp edged and spherical abrasive particles is observed in the micro-cutting and deformation regions. Surface quality produced by abrasive water jet in nano-composites found increased with increase in wt% of Al2O3 when compared to base alloy. Traverse speed, water pressure, and garnet size showed significant effect on surface quality produced by abrasive water jet. Micro-melting was observed in a few regions of the cut surfaces in nano-composites and melted region is affected by oxidation. Formation of short continuous ribbon type chips was also observed in some regions of cut surfaces, indicating the shear mechanism is also involved in the cutting process.

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Abbreviations

AWJ :

abrasive water jet

AWJM:

abrasive water jet machining

AWJC:

abrasive water jet cutting

UAV:

unmanned aerial vehicle

FBU:

flank build-up

MMC:

metal matrix composites

MMNC:

metal matrix nano-composites

SEM:

scanning electron microscopy

EDS:

energy dispersive spectroscopy

XRD:

X-ray diffraction

PCD:

polycrystalline diamond

NTM:

non-traditional machining

LBM:

laser beam machining

LAM:

laser assisted machining

EDM:

electrical discharge machining

DOP:

depth of penetration

Nz:

nozzle (focusing tube) diameter

WP:

water pressure

Ts:

traverse speed

Mf:

mass flow rate

CO2 :

carbon dioxide

SF6 :

sulfur hexafluoride

IDZ:

initial damage zone

SCZ:

smooth cutting zone

RCZ:

rough cutting zone

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Acknowledgments

The authors would like to express their sincere thanks to TEQIP, BMS College of Engineering, Bengaluru, for providing financial assistance to develop nano-composites and facilities to carry out experiments.

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Authors and Affiliations

  1. Department of Mechanical Engineering, BMS College of Engineering, Bengaluru, 560019, India

    C. A. Niranjan, S. Srinivas & M. Ramachandra

  2. Visvesvaraya Technological University, Belagavi, Karnataka, 590018, India

    C. A. Niranjan, S. Srinivas & M. Ramachandra

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  1. C. A. Niranjan
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Correspondence to C. A. Niranjan.

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Niranjan, C.A., Srinivas, S. & Ramachandra, M. Experimental investigations on depth of penetration and surface integrity in AZ91/Al2O3 nano-composites cut by abrasive water jet. Int J Adv Manuf Technol 107, 747–762 (2020). https://doi.org/10.1007/s00170-020-05069-4

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