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Experimental Investigation on Cryogenic Assisted Abrasive Water Jet Machining of Aluminium Alloy

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Abstract

The purpose of the present investigation was to evaluate the abrasive water jet cutting performance by the application of a cryogenic liquid nitrogen jet in the cutting process. This technique was developed for improving the process capability of conventional abrasive water jet machining and enable a higher depth of cut and material removal rate, and better kerf profile and surface integrity. The experiments were conducted on AA5083-H32 aluminium alloy, using two different cutting methods, namely, abrasive water jet cutting and cryogenic assisted abrasive water jet cutting. Both cutting conditions were investigated by varying the water jet pressure, the abrasive mesh size and the abrasive water jet impact angle. Optical microscopy and Scanning Electron Microscope with Energy Dispersive X-ray Spectroscopy was used for studying the micro structure and morphology of the cut surfaces under both cutting conditions. There was an improvement in cutting performance features such as depth of penetration, material removal rate and kerf profile with the use of cryogenic assistance cutting approach. These results were produced due to the beneficial modification of erosion mechanism in the cutting zone as well as a reduction in particle embedment with the cut surface by about 56%.

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Abbreviations

LN2 :

Liquid nitrogen

AWJC:

Abrasive water jet cutting

CAAWJC:

Cryogenic assisted abrasive water jet cutting

EDS:

Energy dispersive spectroscopy

SEM:

Scanning electron microscope

DOP:

Depth of penetration (mm)

MRR:

Material removal rate (mm3/min)

KTR:

Kerf taper ratio

TR:

Traverse rate

Pt:

Maximum peak to valley height (µm)

P:

Pressure (MPa)

MS:

Abrasive mesh size (#)

JIA:

Abrasive water jet impact angle (°)

Mg2Al3 :

Magnesium aluminide (β)

Ra:

Average surface roughness (µm)

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Acknowledgements

The authors acknowledge the Head, Department of Production Technology, Madras Institute of Technology (MIT) campus, Anna University, Chennai-44, for providing the experimental facilities to conduct the research work.

Funding

The authors would like to express their sincere thanks to the Council of Scientific and Industrial Research (CSIR), Government of India, New Delhi, for providing the research fund under the scheme of Senior Research Fellowship (Grant file no. 0.9/468(479)/2014-EMR-I).

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Authors and Affiliations

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

    Yuvaraj Natarajan

  2. Department of Mechanical Engineering, CEG Campus, Anna University, Chennai, 600025, India

    Pradeep Kumar Murugasen

  3. Department of Production Technology, MIT Campus, Anna University, Chennai, 600044, India

    Lenin Raj Sundarajan & Rajadurai Arunachalam

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  1. Yuvaraj Natarajan
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  3. Lenin Raj Sundarajan
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  4. Rajadurai Arunachalam
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Correspondence to Yuvaraj Natarajan.

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Natarajan, Y., Murugasen, P.K., Sundarajan, L.R. et al. Experimental Investigation on Cryogenic Assisted Abrasive Water Jet Machining of Aluminium Alloy. Int. J. of Precis. Eng. and Manuf.-Green Tech. 6, 415–432 (2019). https://doi.org/10.1007/s40684-019-00072-x

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  • DOI: https://doi.org/10.1007/s40684-019-00072-x

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