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Performance Evaluation of Recently Developed New Process HAJM during Machining Hardstone Quartz Using Hot Silicon Carbide Abrasives: an Experimental Investigation and Sustainability Assessment

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Abstract

The better machining capabilities of abrasive jet machining characterized by the absence of thermal distortion make it highly competitive with other cutting processes employing plasma and lasers. In this article, an attempt has been made to combine hot abrasives and compressed air to form a hot abrasive air jet. Hot abrasive jet machining (HAJM) can be applied to various operations such as drilling, surface etching, grooving and micro finishing on the glass and ceramics. This research work involved in cutting performance evaluation of hot abrasive jet machining (HAJM) process and machinability investigation of hardstone quartz concerning surface roughness, taper angle, and material removal rate. Three levels each for air pressure, stand-off distance, and abrasive temperature were selected as control parameters. Experimental results in accordance of Box-Behnken’s design of experiments are analyzed by employing analysis of variance (ANOVA) and statistical technique (here, desirability function analysis of RSM) followed by computational approach (here, genetic algorithm) for experimental investigation, predictive modeling, and multi-response optimization, respectively. Additionally, the effectiveness of proposed two multi-objective optimization techniques are evaluated by confirmation test. Thereafter, the mechanism of material removal has been discussed using a non-contact three-dimensional surface measurement system and scanning electron microscopy images. Finally, a novel approach has been proposed for cost saving economic analysis and sustainability assessment in order to rationalize the operational feasibility and usefulness of hot abrasives in AJM process with an intention to raise the awareness in the manufacturing industry. Analysis of experimental findings revealed that, application of hot abrasives in AJM process have shown an attention in enhancing the cutting performance for material removal. The statistical evaluation and optimization results in this study can contribute to the evaluation of HAJM machinability of hardstone quartz.

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Acknowledgements

This work is supported by Research Promotion Scheme for Research Centres under National Doctoral Fellowship of AICTE, India via. Reference no. 8-32/RIFD/RPS-NDF/Policy-1/2018-19.

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  1. Department of Production Engineering, Veer Surendra Sai University of Technology, Burla, Odisha, 768018, India

    Subhadip Pradhan, Sudhansu Ranjan Das & Debabrata Dhupal

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  1. Subhadip Pradhan
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Correspondence to Sudhansu Ranjan Das.

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Pradhan, S., Das, S.R. & Dhupal, D. Performance Evaluation of Recently Developed New Process HAJM during Machining Hardstone Quartz Using Hot Silicon Carbide Abrasives: an Experimental Investigation and Sustainability Assessment. Silicon 13, 2895–2919 (2021). https://doi.org/10.1007/s12633-020-00641-9

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