PROJECT REPORT
ON
FABRICATION OF MULTI NOZZLE ABRASIVE WATER JET
MACHINING
SL.NO
REG. NO
12800490
G. SELVAKUMAR
12800491
I. SELVAM
10800430
M. THANGAMANI
10800433
S. VIGNESH
BONAFIDE CERTIFICATE
This is to certify that the project entitled
FABRICATION OF MULTI NOZZLE ABRASIVE WATER JET MACHINING
is a Bonafide record work submitted by selvan. _______________________________
Reg No. ________________________ in the Eight semester Diploma in MECHANICAL
ENGINEERING course during the year 2014 2015.
Project Guide
Thiru.B.RAMESH KUMAR, B.E, MBA
Internal Examiner
External Examiner
OBJECTIVES
The prolonged convention of covering the vast syllabus
with in the short of time resulted in lack of technical knowledge and unaware of
modern mechanics and versatile applications. So in order to revise this situation
and have to clear knowledge about modern mechanics and machine tools project
work has been undertaken.
The project resulted in acquiring well defined knowledge
about the modern machine tools and equipments, Mechanism and their versatility.
The Project work includes the Physical and mental co-operation of each individual.
ACKNOWLEDGEMENT
The successful completion of this project is
only due to the joint work of us but also it includes the unforgettable guidance
given by our staff members of department of mechanical Engineering.
We convey our deepest gratitude towards
Thiru. V.SUBBARAJ, M.E, B.Tech.,Ed. Our beloved principal for providing the
opportunity to do this project work and offering the encouragement for successful
completion, which increase our optimism.
We express our sincere thanks to our Head of
Mechanical Engineering Department Thiru. P.MUTHURASU, ME, MIE., Phd
for providing all facilities in time and for this encouragement throughout the
project.
We express heartfelt gratitude to our guide
Thiru. B. RAMESH KUMAR, B.E, MBA., who has given suggestions and
valuable guidance towards our project which made a successful one.
Finally, we pay out hearty thanks to
all the staffs of our department and other who helped either directly or indirectly
for the successful completion of this project.
PREFACE
Project work is a part of regular curricular
activities which is included in the final semester mechanical engineering in
diploma course having a view about vast improvement of technical field.
CONTENTS
TABLE OF CONTENTS
CHAPTER NO.
CHAPTER
1.
INTRODUCTION
2.
LIST OF PARTS
3.
CONSTRUCTION DETAILS
4.
PARTS SPECIFICATION
5.
MACHINING PROCESS
6.
DETAILED DRAWING
7.
DESIGN
8.
WORKING PRINCIPLE
9.
BILL OF MATERIALS
10.
COST ESTIMATION
11.
APPLICATIONS
12.
ADVANTAGES
13.
CONCLUSION
14.
PHOTOGRAPHS
15.
BIBLIOGRAPHY
INTRODUCTION
the material that erodes from the surface of the work piece. The crack caused by
the abrasive water jet impact is now exposed to the water jet.
LIST OF PARTS
The Major Components,
WATER PUMP. ( Self priming - 1/2 HP)
COIL WINDING.
MULTI DIMENSIONAL NOZZLE.
SLEEVE.
CASING.
ABRASIVE.
STAND.
SQUARE CHANNEL.
TOOL HOLDER.
1 BALL VALVE. (M.S )
1 BALL VALVE. (PVC)
HOSES.
WATER TANK.
CONSTRUCTION DETAILS
Reservoir: It is used for storing water that is to be used in the machining operation.
Pump:
Water jet cutting systems utilize either the older, more complex hydraulic
Control Valve: It controls the direction and pressure of pressurized water that is to
be supplied to the nozzle.
Nozzle: It renders the pressurized water as a water jet at high velocity. for water-only
nozzle designed for cutting of soft material, the venturi section and mixing tube are
eliminated and the coherent jet of water alone cuts the material. In order for the
aspiration nozzle to cut efficiently and with long component life, it is critical that the
orifice be carefully aligned with the centreline of the mixing tube
PARTS SPECIFICATION
1. Water Pump
Power
Voltage
Watt
:
:
:
0.5 Hp
220V
7 watts
2. Reservoir tank:
Capacity :
20 liter
1 Ball Valve
Size
Pressure
:
:
4 mm
8 -10 Kpa
Size
Pressure
:
:
5 mm
10 -12 Kpa
Size
Pressure
:
:
6 mm
10 -15 Kpa
4. Nozzle :
MACHINING PROCESS
Abrasive water jet technology evolved in the post war era as research
around the world searched for new methods of efficient cutting systems. a method
for cutting plastic shapes using a thin stream high pressure abrasive water jet, but
those materials, like paper, were soft materials, ultra high pressure liquid cutting to
cut hard materials. This system used a 100,000 psi ( 690 Mpa ) pump to deliver a
hypersonic liquid jet that could cut high strength alloys such as PH15 7- MO
stainless steel.
1. Mechanical process
- USM - Ultrasonic Machining
- AJM Abrasive Jet Machining
- WJM and AWJM
2. Thermal process
3. Electrical process
4. Chemical process
- Chemical milling
- Photo chemical machining
ABRASIVE PROCESS
Abrasive ceramics are used to wear, grind or
cut away other material, which necessarily is softer. Therefore, the prime requisite
for this group of materials is hardness or wear resistance; in addition, a high degree
of toughness is essential to ensure that the abrasive particles do not easily fracture.
Furthermore, high temperatures may be produced from abrasive frictional forces,
so some re-factories is also desirable.
Diamonds, both natural and synthetic, are
utilizes as abrasives; however, they are relatively expensive. The more common
ceramic abrasives include silicon carbide, tungsten carbide (WC), aluminum oxide
(or corundum) and silica sand.
Abrasive are used in several forms bonded
to giving wheels, as coated abrasives and as loose grains. In the first case, the
abrasive particles are bonded to a wheel by means of a glassy ceramic or an
organic resin. The surface structure should contain some porosity; a continual flow
of air currents or liquid coolants within the pores that surround the refractory
grains will prevent excessive heating.
Coated abrasives are those in which an
abrasive powder is coated on some type of paper or cloth material; sandpaper is
probably the most familiar example. Wood, metals, ceramics and plastics are all
frequently ground and polished using this form of abrasive.
Grinding, lapping and polishing wheels often
employ loose abrasive grains that are delivered in some type of oil or water
based vehicle. Diamonds, corundum, silicon carbide and rouge (an iron oxide) are
used in loose form over a variety of grain size ranges.
ABRASIVE
RESERVOIR
FLOW
CONTROL
1 VALVE
WATER
TANK
MOTOR-PUMP
1VALVE
WORK
PIECE
3D - DESIGN
WORKING PRINCIPLE:
Typical abrasive water jet machine is made up of 6
main parts namely; a water tank, a nozzle, sand reservoir, and a motor. The motor is
usually connected to the piston pump which pumps water from the tank through a
tube. The water is then mixed with an abrasive (usually sand) in the mixing
chamber. The mixture comes out through a nozzle at high pressure aimed sharply on
the sheet of metal or material to be machined.
Water from the Tank is pumped to the reservoir using a hydraulic pump.
The reservoir increases the pressure of the water to the required level.
Usually, the water is pressurized to 200 to 400 MPa.
Pressurized water is then sent to the accumulator. The accumulator
temporarily stores the pressurized water.
Pressurized water then enters variable sized nozzle by passing through the
control valve and flow regulator.
Control valve controls the direction of water and limits the pressure of water
under permissible limits.
Flow regulator regulates and controls the flow rate of water.
Pressurized water finally enters the nozzle. Here, it expands with a
tremendous increase in its kinetic energy. High velocity water jet is
produced by the nozzle.
When this water jet strikes the workpiece, stresses are induced. These
stresses are used to remove material from the workpiece.
The water used in water jet machining may or may not be used with
stabilizers. Stabilizers are substances that improve the quality of water jet by
preventing its fragmentation.
1. Material thickness:
The speed is related to thickness in a nonlinear manner basically for half the
thickness, the speed is more than two times greater.
2. Diameter:
A thicker nozzle carries more energy thus increasing the cutting speed. A nozzle of
twice the diameter carries four times the volume of high pressure water; the speed
increase however is only 80%. Therefore it often is practical to use smaller nozzles
with multiple heads running in parallel.
3. Abrasive Feeding:
The speed can be also increased by increasing the Abrasive feed rate. Here again, a
doubling of the feed rate does not result in a doubled cutting speed depending on
the thickness the result is an increase of 20-40%
4. Pressure:
A higher cutting pressure brings more energy into the workpiece, thus increasing
the cutting power. At higher pressures, the abrasive feed rates can be increased
without blocking the focusing tube. Both effects lead to the conclusion that by a
pressure increase of 10%, more than 10% cutting speed can be achieved
5. Cut quality:
BILL OF MATERIALS
Sl. No
COMPONENTS
MATERIALS
QTY
1.
WATER PUMP.
( Self priming - 1/2 HP)
C.I
1 No.
COIL WINDING
COPPER
AS PER
REQIREMENT.
M.S
3 Nos.
4.
MULTI DIMENSIONAL
NOZZLE
SLEEVE
M.S
1 No.
5.
CASING
M.S
6.
ABRASIVE
1 No.
AS PER
REQIREMENT.
7.
STAND
M.S
1 No.
8.
SQUARE CHANNEL
M.S
12 Nos.
9.
TOOL HOLDER
M.S
1 No.
10.
1 BALL VALVE
M.S
2 Nos.
11.
1 BALL VALVE
PVC
3 Nos.
AS PER
12.
SECTION HOSE
PLASTIC
2.
3.
REQIREMENT.
13.
14.
WATER TANK.
M.S.
2 Nos.
PLASTIC
1 No
COST ESTIMATION
The selling price of the products has the following components.
1. Prime Cost.
2. Factory Cost.
3. Production Cost.
4. Total Cost or Sales Cost.
1. Prime Cost :
= Direst Material Cost + Direct Cost + Direct Expenses ( if any)
2. Factory Cost:
= Prime cost + factory overheads
3. Production Cost:
= Factory cost + Administrative overheads
4. Total Cost or Sales Cost:
Sometimes administrative and sales overheads are put together and
given as general overheads. In such cases
Total cost = Factory + General overheads
Sales price
It profit is added to the total cost of product, sales price is arrived. The customers
get the article by paying the price named as selling price.
Sales price = Total cost + profit
COST ESTIMATION
Direct Material Cost :
1. Design Cost
2. Fabrication Cost
3. Painting Cost
TOTAL
Rs. 1950 /-
Rs. 1000 /-
Rs.2950 /-
% of prime cost
TOTAL
Total Cost
Rs. 950 /-
Rs. 3900 /-
APPLICATIONS
The applications and materials, which are generally machined using AWJ, are
given below:
Paint removal.
Cleaning.
Cutting soft materials.
Cutting frozen meat.
Textile, Leather industry.
Mass Immunization.
Surgery.
Peening.
Cutting.
Pocket Milling.
Drilling.
Turning.
Nuclear plant Dismantling materials.
Steels.
Non ferrous alloys.
Ti alloys, Ni alloys.
Polymers.
Honeycomb.
ADVANTAGES
Cheaper than other processes.
Cut virtually any material. ( pre hardened steel, copper, mild steel,
brass, aluminum; brittle materials like glass, ceramic, quartz, stone )
Cut thin stuff, or thick stuff.
Make all sorts of shapes with only one tool.
No heat generated.
Leaves a satin smooth finish, thus reducing secondary operations.
Clean cutting process without gasses or oils.
Modern systems are now very easy to learn.
Are very safe.
Machine stacks of thin parts all at once.
Unlike machining or grinding, abrasive water jet cutting does not
produce any dust or particles that are harmful if inhaled.
The kerfs width in abrasive water jet cutting is very small, and very little
material is wasted.
Abrasive water jet cutting can be easily used to produce prototype parts
very efficiently. This is much faster and cheaper than drawing detailed
prints of a part and then having a machinist cut the part out.
CONCLUSION
The projects work provides the opportunity
for students live us to bring out the hidden regarding the mechanical engineering
aspect. The work involved in it like selecting materials, designing machine
handling, fabrication, cost etc,. Which all carried out independently of our own
.This makes our students hopeful.
BIBLIOGRAPHY
TEXT BOOK:
TITLE:
AUTHOR:
TITLE
AUTHOR:
TITLE
AUTHOR:
ANDRAS W. MOMBER.
WEBSITE:
http://auto.howstuffworks.com
http://www.google.com
http://www.wikipedia.com