- Email: [email protected]
Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE)
Materials Today: Proceedings xxx (xxxx) xxx
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE) Vootkuri Naveen Reddy ⇑, Bellam Venkatesh Department of Mechanical Engineering, CMR Institute of Technology, Hyderabad, India
a r t i c l e
i n f o
Article history: Received 16 August 2019 Accepted 18 August 2019 Available online xxxx Keywords: GLARE (Glass Laminate Aluminum Reinforced Epoxy) Abrasive water jet machine Microscope Delamination extent Surface roughness
a b s t r a c t The aim of the Current study is to optimize the parameters of AWJM (Abrasive water jet machine) while machining of GLARE composites. The machining of fiber metal laminates quite difficult to without damage in traditional machining process. To defeat this problem advanced manufacturing process AWJM was employed. In present study conducting the drilling operation on GLARE under different conditions of input parameters such as Stand off distance, Traverse rate, Abrasive mass flow rate, water jet pressure. Response surface methodology technique ANOVA (Analysis of variance) was employed to measure the impact of input parameters on response variables such as delamination and surface roughness. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 1st International Conference on Manufacturing, Material Science and Engineering.
1. Introduction Fiber metal laminates (FML) are group of materials, these are fabricated by joining glass/epoxy layers within metal layers. now a days weight reduction of the component is one of the main aim in many industrial sectors, due to this utilizing of the composites are increased day to day . In present study conducting the experiment on Glass laminate Aluminium reinforced epoxy (GLARE) [1].it is a popular fiber metal laminate. GLARE composite materials are employed in several industrial applications because of the benefits they provide compared to different materials, the wide usage of GLARE in the fuselage part of airbus. These benefits are the sunshine weight with the high strength, sensible toughness, high corrosion resistance, high thermal resistance [2]. In current study aim is to optimize the parameters of AWJM (Abrasive water jet machine) while machining of GLARE composites The machining of Fiber metal laminates quite difficult to without damage in traditional machining process due to their homogeneity, anisotropic, and thermal sensitivity. To defeat this problem go through the advanced manufacturing process AWJM (Abrasive water jet machine) will be used [3]. It is a non-traditional machining process it has some advantages those are high flexibility, no heat applied on the material, no chip formation, accuracy. However
⇑ Corresponding author. E-mail address: [email protected] (V. Naveen Reddy).
in non-traditional machining process also face the some problems [4]. 2. Experimental work In this project AWJ machine was used which is shown in Fig. 2 is used to machining the work piece under different conditions. AWJM contains the Abrasive feeding system with Abrasive feed meter. The maximum pump pressure of machine is 260 MPa. The positional and repeat accuracy of the machine is ±0.04 mm. As the objective of present work is to minimize surface roughness and delamination, in this study using the garnet abrasives of mesh size # 80. Purifier water tank is used for the inlet to the AWJM and these water again reused. GLARE component have dimensions of 150 150 4 mm and 150 150 8 mm, 150 150 12 mm Properties of the work piece are described in Table 1. Thickness of the component is 4 mm, 8mm, 12 mm are used in current study. 2.1. Material composition and fabrication process 2.1.1. GLARE features, characteristics, and properties The main purpose of preparing a GLARE type FML to get the advantages of glass/epoxy and as well as metal due to the combination of these two types it provides the superior properties. GLARE contains the thin sheet of Aluminum with glass fibers bonded together in epoxy adhesive laid up within. Al have the different types of thicknesses its range from 0.2 to 0.5 mm. The
https://doi.org/10.1016/j.matpr.2019.08.245 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 1st International Conference on Manufacturing, Material Science and Engineering.
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
2
V. Naveen Reddy, B. Venkatesh / Materials Today: Proceedings xxx (xxxx) xxx Table 1 Mechanical properties of GLARE. Property
Value
Strength Young’s modules Strain at failure
50 MPa 1.7 GPa 5–10% (Depends on strain rate)
GLARE contains the unidirectional S-glass fibers bonded in an adhesive. Mechanical properties of GLARE and Unidirectional glass fiber will be illustrated in Tables 1 and 2.
Fig. 1. 4 mm thickness of GLARE.
2.1.2. GLARE fabrication method The material selected for hole making operation is Glass Laminated Aluminium Reinforce Epoxy Resin and specimens are fabricated by hand layup process using epoxy resin. For the experimentation each specimen cut by 150 mm 150 mm size with 4 mm ,8mm and 12 mm thickness by varying the fiber orientation as 0, 45 and 90. The below Figs. 1–3 shows the different thicknesses of GLARE work pieces.
2.2. Machining setup Experimental setup of AWJM line diagram will be shown in Fig. 4. In current project Germany based Technolgies 3015 model three axis Abrasive water jet machine was used. The size of the machine is 3 m (x-axis) 1.5 m (y-axis) 300 mm (z-axis). Configurations of abrasive water jet machine will shown in Table 3. The position and cutting speed of the cutting head was controlled by CNC controller.
Fig. 2. 8 mm thickness of GLARE.
2.3. Experimental procedure Present study total of 31 experiments were conducted on the GLARE work piece under different process parameters with respect response variables. After completion of the drilling operation, each hole was chances to get delamination so delamination analysis was carried by each hole with help of AliconaÒ focus variation microscopy, For outer hole delamination extent was addressed with the comparing actual hole size measurement was taken by placed the workpiece on horizontal bed of microscope. The delamination extent was measure with help of scanned images these addressed through microscope.
Fig. 3. 12 mm thickness of GLARE.
3. Results and discussion for delamination extent During the drilling of GLARE composites with AWJM, there are so many factors affects the quality of drilled hole. Behavior of delamination extent of exit hole and actual hole size were addressed. The entire analysis was taken with the help of software MINITAB 16.
Fig. 4. Schematic diagram of AWJM.
3.1. Morphology for drilled hole
Table 2 Mechanical properties of glass fiber. Property
Value
Strength Young’s modules Strain at failure
4000 MPa 88 GPa 4.45%
Delamination factor was measure under different conditions of process variables those are Stand off distance and Abrasive mass flow rate. The below mathematical formula was used to finding the Delamination factor.
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
3
V. Naveen Reddy, B. Venkatesh / Materials Today: Proceedings xxx (xxxx) xxx Table 3 Layup sequence of glass fiber. Layup Sequence
Thickness (mm)
Al/0/90/Al/90/0/Al Al/0/90/Al/90/0/Al/0/90/Al/90/0/Al [Al/0/+45/Al/45/90/+45/Al/45/0/+45/Al] symmetric
4 8 12
Where Al = Aluminum.
Dext ¼ Dmax Dnom ; Fig. 6. 8 mm thickness.
where Dext = Extended Diameter of the hole. Dmax = Maximum diameter of the hole. Dnom = Nominal diameter of the hole. The extent diameters of the drilled work-pieces are measured with the help of METASCOPE METALLURGICAL MICROSCOPE. The Figs. 5–7 shows the actual size of the holes of different thicknesses.
Delamination Factor ¼ MaximumDiameter=NominlDiameter D:F ¼ Dmax=D
Fig. 7. 12 mm thickness.
ð1Þ 3.2. Impact of the input (Cutting) parameters on the Delamination extent 3.2.1. Effect of water jet pressure on Delamination extent Based on Table 4 results addressed the following results those are. With the increasing of water jet pressure Delamination Extent will be also increased at the level of water jet pressure is (180– 240 MPa), the Delamination extent is moderate at 300 MPa of Water jet pressure. Finally concluded that water jet pressure governs the Delamination extent (Fig. 8).
Table 4 AWJM configurations. Property
Value
Pressure of the water Sand flow Orifice diameter Nozzle Diameter Stand off distance Traverse speed Abrasive type
3800 bar 300–350 (g/min) 0.35 mm 1.1 mm 2 mm 350 mm/min Garnet mesh size of #80
3.2.2. Effect of Abrasive mass flow rate on Delamination extent Based on Table 4 results addressed the following results those are. with the increasing of Abrasive mass flow rate Delamination Extent will be also increased at the level of Abrasive mass flow rate is (100 to 150 g/min), the Delamination extent is moderate at 200 g/min of Abrasive mass flow rate (Fig. 9). 3.2.3. Effect of standoff distance on Delamination extent Based on Table 5 results addressed the following results those are. With the increasing of standoff distance Delamination Extent will be also increased at the level of standoff distance is (1.5– 3 mm), the Delamination extent is moderate at 4.5 mm of Standoff distance (Fig. 10). 3.2.4. Effect of Traverse rate on Delamination extent Based on Table 4 results addressed the following results those are.
Fig. 8. Line graph of water jet pressure Vs delamination extent.
With the increasing of Traverse rate (mm/s) Delamination Extent will be also increased at the level of the traverse rate is 2–4 mm Delamination extent is moderate at 6 mm of Traverse rate (Fig. 11). 3.3. Impact of the input (Cutting) parameters on the Surface roughness
Fig. 5. 4 mm thickness.
3.3.1. Effect of water jet pressure on Surface roughness Based on Table 4 results addressed the following results those are. With the increasing of water jet pressure Surface roughness will be also increased at the level of water jet pressure is (180– 240 MPa), the Surface roughness is moderate at 300 MPa of Water
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
4
V. Naveen Reddy, B. Venkatesh / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 9. Line graph of abrasive mass flow rate Vs delamination extent.
Fig. 10. Line stand off distance Vs delamination extent.
jet pressure. Finally concluded that water jet pressure governs the Delamination extent (Fig. 12).
3.3.2. Effect of Abrasive mass flow rate on Surface roughness Based on Table 4 results addressed the following results those are. With the increasing of Abrasive mass flow rate Surface roughness will be also increased at the level of Abrasive mass flow rate is (100–150 g/min), the Surface roughness is moderate at 200 g/ min of Abrasive mass flow rate (Fig. 13).
3.3.3. Effect of standoff distance on Surface roughness Based on Table 5 results addressed the following results those are.
Fig. 11. Line graph of traverse rate Vs delamination extent.
Table 5 Results with corresponding input parameters. Experiment Number
Pressure (Mpa)
Abrasive mass Flow rate (g/min)
Traverse speed (mm/s)
Standoff distance (mm)
Thickness of Material (mm)
Surface Roughness (lmRa)
Delamination Factor (mm)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
180 240 180 240 180 300 240 180 240 180 240 300 300 240 240 240 180 300 240 180 300 240 240 180 240 300 240 300 300 300 180
200 150 100 100 150 200 200 150 100 100 150 200 200 150 100 100 150 200 200 150 100 100 150 200 200 150 100 100 150 200 200
2 4 6 2 4 6 6 4 2 2 4 6 6 4 2 6 4 2 6 4 2 2 4 6 6 4 2 2 4 6 2
4.5 3 1.5 1.5 3 4.5 4.5 3 1.5 4.5 3 1.5 3 4.5 1.5 3 4.5 1.5 3 4.5 4.5 3 1.5 1.5 3 4.5 4.5 3 1.5 1.5 3
4 8 12 4 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12
0.133 0.143 0.164 0.135 0.136 0.152 0.164 0.137 0.145 0.165 0.147 0.155 0.164 0.145 0.154 0.166 0.143 0.155 0.165 0.142 0.153 0.170 0.132 0.144 0.176 0.133 0.145 0.166 0.134 0.143 0.165
0.780 0.890 0.990 0.670 0.860 0.970 0.650 0.774 0.890 0.654 0.776 0.900 0.670 0.768 0.890 0.456 0.800 0.900 0.670 0.550 0.780 0.890 0.980 0.670 0.870 0.980 0.656 0.890 0.789 0.890 0.980
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
V. Naveen Reddy, B. Venkatesh / Materials Today: Proceedings xxx (xxxx) xxx
5
Fig. 15. Line graph of traverse rate Vs surface roughness. Fig. 12. Line graph of water jet pressure Vs surface roughness.
the Surface roughness is moderate at 4.5 mm of Standoff distance (Fig. 14). 3.3.4. Effect of Traverse rate on Surface roughness Based on Table 5 results addressed the following results those are. With the increasing of Traverse rate (mm/s) Surface roughness will be also increased at the level of the traverse rate is 2–4 mm Surface roughness is moderate at 6 mm of Traverse rate (Fig. 15). 4. Conclusions In current project focused on the Delamination and Surface roughness of drilled hole with AWJM. Here addressed some of the data about delamination extent and surface roughness were expressed below. Fig. 13. Line graph of abrasive mass flow rate Vs surface roughness.
(1) Some of the most significant parameters to control the surface roughness are abrasive water jet pressure and TR (traverse rate). (2) Surface roughness will be decreased when abrasive water jet pressure increased. (3) Surface roughness will be decrease when traverse rate decreased. (4) At low abrasive water jet pressure delamination and fiber pull out will be occurred. (5) At high Stand off distance delamination and fiber pull out will be occurred.
References
Fig. 14. Line graph of stand off distance Vs surface roughness.
With the increasing of standoff distance Surface roughness will be also increased at the level of standoff distance is (1.5–3 mm),
[1] M. Ramulu, D. Arola, The influence of abrasive waterjet cutting conditions on the surface quality of graphite/epoxy laminates, Int. J. Mach. Tools Manufacture 343 (1994) 295–313, https://doi.org/10.1016/08906955(94)90001-9. [2] D. Arola, M. Ramulu, A study of kerf characteristics in abrasive water jet machining of graphite/epoxy composite, J. Eng. Mater. Technol. 1182 (1996) 256–265, https://doi.org/10.1115/1.2804897. [3] J. Wang, Abrasive Waterjet machining of polymer matrix composites – Cutting performance. Erosive process and predictive models, Int. J. Adv. Manuf. Technol. 1510 (1999) 757–768, https://doi.org/10.1007/s001700050129. [4] J. Wang, H. Liu, Profile cutting on alumina ceramics by abrasive waterjet Part 1: Experimental investigation, Proc. Inst. Mech. Eng. 2205 (2006) 703–714, https:// doi.org/10.1243/09544062JMES207A.
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
Contents lists available at ScienceDirect
Materials Today: Proceedings journal homepage: www.elsevier.com/locate/matpr
Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE) Vootkuri Naveen Reddy ⇑, Bellam Venkatesh Department of Mechanical Engineering, CMR Institute of Technology, Hyderabad, India
a r t i c l e
i n f o
Article history: Received 16 August 2019 Accepted 18 August 2019 Available online xxxx Keywords: GLARE (Glass Laminate Aluminum Reinforced Epoxy) Abrasive water jet machine Microscope Delamination extent Surface roughness
a b s t r a c t The aim of the Current study is to optimize the parameters of AWJM (Abrasive water jet machine) while machining of GLARE composites. The machining of fiber metal laminates quite difficult to without damage in traditional machining process. To defeat this problem advanced manufacturing process AWJM was employed. In present study conducting the drilling operation on GLARE under different conditions of input parameters such as Stand off distance, Traverse rate, Abrasive mass flow rate, water jet pressure. Response surface methodology technique ANOVA (Analysis of variance) was employed to measure the impact of input parameters on response variables such as delamination and surface roughness. Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 1st International Conference on Manufacturing, Material Science and Engineering.
1. Introduction Fiber metal laminates (FML) are group of materials, these are fabricated by joining glass/epoxy layers within metal layers. now a days weight reduction of the component is one of the main aim in many industrial sectors, due to this utilizing of the composites are increased day to day . In present study conducting the experiment on Glass laminate Aluminium reinforced epoxy (GLARE) [1].it is a popular fiber metal laminate. GLARE composite materials are employed in several industrial applications because of the benefits they provide compared to different materials, the wide usage of GLARE in the fuselage part of airbus. These benefits are the sunshine weight with the high strength, sensible toughness, high corrosion resistance, high thermal resistance [2]. In current study aim is to optimize the parameters of AWJM (Abrasive water jet machine) while machining of GLARE composites The machining of Fiber metal laminates quite difficult to without damage in traditional machining process due to their homogeneity, anisotropic, and thermal sensitivity. To defeat this problem go through the advanced manufacturing process AWJM (Abrasive water jet machine) will be used [3]. It is a non-traditional machining process it has some advantages those are high flexibility, no heat applied on the material, no chip formation, accuracy. However
⇑ Corresponding author. E-mail address: [email protected] (V. Naveen Reddy).
in non-traditional machining process also face the some problems [4]. 2. Experimental work In this project AWJ machine was used which is shown in Fig. 2 is used to machining the work piece under different conditions. AWJM contains the Abrasive feeding system with Abrasive feed meter. The maximum pump pressure of machine is 260 MPa. The positional and repeat accuracy of the machine is ±0.04 mm. As the objective of present work is to minimize surface roughness and delamination, in this study using the garnet abrasives of mesh size # 80. Purifier water tank is used for the inlet to the AWJM and these water again reused. GLARE component have dimensions of 150 150 4 mm and 150 150 8 mm, 150 150 12 mm Properties of the work piece are described in Table 1. Thickness of the component is 4 mm, 8mm, 12 mm are used in current study. 2.1. Material composition and fabrication process 2.1.1. GLARE features, characteristics, and properties The main purpose of preparing a GLARE type FML to get the advantages of glass/epoxy and as well as metal due to the combination of these two types it provides the superior properties. GLARE contains the thin sheet of Aluminum with glass fibers bonded together in epoxy adhesive laid up within. Al have the different types of thicknesses its range from 0.2 to 0.5 mm. The
https://doi.org/10.1016/j.matpr.2019.08.245 2214-7853/Ó 2019 Elsevier Ltd. All rights reserved. Selection and peer-review under responsibility of the scientific committee of the 1st International Conference on Manufacturing, Material Science and Engineering.
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
2
V. Naveen Reddy, B. Venkatesh / Materials Today: Proceedings xxx (xxxx) xxx Table 1 Mechanical properties of GLARE. Property
Value
Strength Young’s modules Strain at failure
50 MPa 1.7 GPa 5–10% (Depends on strain rate)
GLARE contains the unidirectional S-glass fibers bonded in an adhesive. Mechanical properties of GLARE and Unidirectional glass fiber will be illustrated in Tables 1 and 2.
Fig. 1. 4 mm thickness of GLARE.
2.1.2. GLARE fabrication method The material selected for hole making operation is Glass Laminated Aluminium Reinforce Epoxy Resin and specimens are fabricated by hand layup process using epoxy resin. For the experimentation each specimen cut by 150 mm 150 mm size with 4 mm ,8mm and 12 mm thickness by varying the fiber orientation as 0, 45 and 90. The below Figs. 1–3 shows the different thicknesses of GLARE work pieces.
2.2. Machining setup Experimental setup of AWJM line diagram will be shown in Fig. 4. In current project Germany based Technolgies 3015 model three axis Abrasive water jet machine was used. The size of the machine is 3 m (x-axis) 1.5 m (y-axis) 300 mm (z-axis). Configurations of abrasive water jet machine will shown in Table 3. The position and cutting speed of the cutting head was controlled by CNC controller.
Fig. 2. 8 mm thickness of GLARE.
2.3. Experimental procedure Present study total of 31 experiments were conducted on the GLARE work piece under different process parameters with respect response variables. After completion of the drilling operation, each hole was chances to get delamination so delamination analysis was carried by each hole with help of AliconaÒ focus variation microscopy, For outer hole delamination extent was addressed with the comparing actual hole size measurement was taken by placed the workpiece on horizontal bed of microscope. The delamination extent was measure with help of scanned images these addressed through microscope.
Fig. 3. 12 mm thickness of GLARE.
3. Results and discussion for delamination extent During the drilling of GLARE composites with AWJM, there are so many factors affects the quality of drilled hole. Behavior of delamination extent of exit hole and actual hole size were addressed. The entire analysis was taken with the help of software MINITAB 16.
Fig. 4. Schematic diagram of AWJM.
3.1. Morphology for drilled hole
Table 2 Mechanical properties of glass fiber. Property
Value
Strength Young’s modules Strain at failure
4000 MPa 88 GPa 4.45%
Delamination factor was measure under different conditions of process variables those are Stand off distance and Abrasive mass flow rate. The below mathematical formula was used to finding the Delamination factor.
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
3
V. Naveen Reddy, B. Venkatesh / Materials Today: Proceedings xxx (xxxx) xxx Table 3 Layup sequence of glass fiber. Layup Sequence
Thickness (mm)
Al/0/90/Al/90/0/Al Al/0/90/Al/90/0/Al/0/90/Al/90/0/Al [Al/0/+45/Al/45/90/+45/Al/45/0/+45/Al] symmetric
4 8 12
Where Al = Aluminum.
Dext ¼ Dmax Dnom ; Fig. 6. 8 mm thickness.
where Dext = Extended Diameter of the hole. Dmax = Maximum diameter of the hole. Dnom = Nominal diameter of the hole. The extent diameters of the drilled work-pieces are measured with the help of METASCOPE METALLURGICAL MICROSCOPE. The Figs. 5–7 shows the actual size of the holes of different thicknesses.
Delamination Factor ¼ MaximumDiameter=NominlDiameter D:F ¼ Dmax=D
Fig. 7. 12 mm thickness.
ð1Þ 3.2. Impact of the input (Cutting) parameters on the Delamination extent 3.2.1. Effect of water jet pressure on Delamination extent Based on Table 4 results addressed the following results those are. With the increasing of water jet pressure Delamination Extent will be also increased at the level of water jet pressure is (180– 240 MPa), the Delamination extent is moderate at 300 MPa of Water jet pressure. Finally concluded that water jet pressure governs the Delamination extent (Fig. 8).
Table 4 AWJM configurations. Property
Value
Pressure of the water Sand flow Orifice diameter Nozzle Diameter Stand off distance Traverse speed Abrasive type
3800 bar 300–350 (g/min) 0.35 mm 1.1 mm 2 mm 350 mm/min Garnet mesh size of #80
3.2.2. Effect of Abrasive mass flow rate on Delamination extent Based on Table 4 results addressed the following results those are. with the increasing of Abrasive mass flow rate Delamination Extent will be also increased at the level of Abrasive mass flow rate is (100 to 150 g/min), the Delamination extent is moderate at 200 g/min of Abrasive mass flow rate (Fig. 9). 3.2.3. Effect of standoff distance on Delamination extent Based on Table 5 results addressed the following results those are. With the increasing of standoff distance Delamination Extent will be also increased at the level of standoff distance is (1.5– 3 mm), the Delamination extent is moderate at 4.5 mm of Standoff distance (Fig. 10). 3.2.4. Effect of Traverse rate on Delamination extent Based on Table 4 results addressed the following results those are.
Fig. 8. Line graph of water jet pressure Vs delamination extent.
With the increasing of Traverse rate (mm/s) Delamination Extent will be also increased at the level of the traverse rate is 2–4 mm Delamination extent is moderate at 6 mm of Traverse rate (Fig. 11). 3.3. Impact of the input (Cutting) parameters on the Surface roughness
Fig. 5. 4 mm thickness.
3.3.1. Effect of water jet pressure on Surface roughness Based on Table 4 results addressed the following results those are. With the increasing of water jet pressure Surface roughness will be also increased at the level of water jet pressure is (180– 240 MPa), the Surface roughness is moderate at 300 MPa of Water
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
4
V. Naveen Reddy, B. Venkatesh / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 9. Line graph of abrasive mass flow rate Vs delamination extent.
Fig. 10. Line stand off distance Vs delamination extent.
jet pressure. Finally concluded that water jet pressure governs the Delamination extent (Fig. 12).
3.3.2. Effect of Abrasive mass flow rate on Surface roughness Based on Table 4 results addressed the following results those are. With the increasing of Abrasive mass flow rate Surface roughness will be also increased at the level of Abrasive mass flow rate is (100–150 g/min), the Surface roughness is moderate at 200 g/ min of Abrasive mass flow rate (Fig. 13).
3.3.3. Effect of standoff distance on Surface roughness Based on Table 5 results addressed the following results those are.
Fig. 11. Line graph of traverse rate Vs delamination extent.
Table 5 Results with corresponding input parameters. Experiment Number
Pressure (Mpa)
Abrasive mass Flow rate (g/min)
Traverse speed (mm/s)
Standoff distance (mm)
Thickness of Material (mm)
Surface Roughness (lmRa)
Delamination Factor (mm)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
180 240 180 240 180 300 240 180 240 180 240 300 300 240 240 240 180 300 240 180 300 240 240 180 240 300 240 300 300 300 180
200 150 100 100 150 200 200 150 100 100 150 200 200 150 100 100 150 200 200 150 100 100 150 200 200 150 100 100 150 200 200
2 4 6 2 4 6 6 4 2 2 4 6 6 4 2 6 4 2 6 4 2 2 4 6 6 4 2 2 4 6 2
4.5 3 1.5 1.5 3 4.5 4.5 3 1.5 4.5 3 1.5 3 4.5 1.5 3 4.5 1.5 3 4.5 4.5 3 1.5 1.5 3 4.5 4.5 3 1.5 1.5 3
4 8 12 4 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12 4 8 12
0.133 0.143 0.164 0.135 0.136 0.152 0.164 0.137 0.145 0.165 0.147 0.155 0.164 0.145 0.154 0.166 0.143 0.155 0.165 0.142 0.153 0.170 0.132 0.144 0.176 0.133 0.145 0.166 0.134 0.143 0.165
0.780 0.890 0.990 0.670 0.860 0.970 0.650 0.774 0.890 0.654 0.776 0.900 0.670 0.768 0.890 0.456 0.800 0.900 0.670 0.550 0.780 0.890 0.980 0.670 0.870 0.980 0.656 0.890 0.789 0.890 0.980
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245
V. Naveen Reddy, B. Venkatesh / Materials Today: Proceedings xxx (xxxx) xxx
5
Fig. 15. Line graph of traverse rate Vs surface roughness. Fig. 12. Line graph of water jet pressure Vs surface roughness.
the Surface roughness is moderate at 4.5 mm of Standoff distance (Fig. 14). 3.3.4. Effect of Traverse rate on Surface roughness Based on Table 5 results addressed the following results those are. With the increasing of Traverse rate (mm/s) Surface roughness will be also increased at the level of the traverse rate is 2–4 mm Surface roughness is moderate at 6 mm of Traverse rate (Fig. 15). 4. Conclusions In current project focused on the Delamination and Surface roughness of drilled hole with AWJM. Here addressed some of the data about delamination extent and surface roughness were expressed below. Fig. 13. Line graph of abrasive mass flow rate Vs surface roughness.
(1) Some of the most significant parameters to control the surface roughness are abrasive water jet pressure and TR (traverse rate). (2) Surface roughness will be decreased when abrasive water jet pressure increased. (3) Surface roughness will be decrease when traverse rate decreased. (4) At low abrasive water jet pressure delamination and fiber pull out will be occurred. (5) At high Stand off distance delamination and fiber pull out will be occurred.
References
Fig. 14. Line graph of stand off distance Vs surface roughness.
With the increasing of standoff distance Surface roughness will be also increased at the level of standoff distance is (1.5–3 mm),
[1] M. Ramulu, D. Arola, The influence of abrasive waterjet cutting conditions on the surface quality of graphite/epoxy laminates, Int. J. Mach. Tools Manufacture 343 (1994) 295–313, https://doi.org/10.1016/08906955(94)90001-9. [2] D. Arola, M. Ramulu, A study of kerf characteristics in abrasive water jet machining of graphite/epoxy composite, J. Eng. Mater. Technol. 1182 (1996) 256–265, https://doi.org/10.1115/1.2804897. [3] J. Wang, Abrasive Waterjet machining of polymer matrix composites – Cutting performance. Erosive process and predictive models, Int. J. Adv. Manuf. Technol. 1510 (1999) 757–768, https://doi.org/10.1007/s001700050129. [4] J. Wang, H. Liu, Profile cutting on alumina ceramics by abrasive waterjet Part 1: Experimental investigation, Proc. Inst. Mech. Eng. 2205 (2006) 703–714, https:// doi.org/10.1243/09544062JMES207A.
Please cite this article as: V. Naveen Reddy and B. Venkatesh, Optimization of parameters in abrasive water jet machining of glass laminate aluminium reinforced epoxy (GLARE), Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.08.245