Abrasive Water Jet Cutting (AWJC)
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Questions and Answers

What is the typical range of nozzle orifice diameters used in abrasive water jet cutting (AWJC)?

  • $0.075$ to $1.0$ mm
  • $0.2$ to $1.4$ MPa
  • $2.5$ to $5.0$ m/s
  • $0.25$ to $0.63$ mm (correct)

    • What is the typical range of abrasive particle sizes used in abrasive water jet cutting (AWJC)?

  • $0.25$ kg/min
  • $15$ to $40$ μm
  • $60$ to $120$ μm (correct)
  • $400$ MPa

    • What is the typical water pressure used in abrasive water jet cutting (AWJC)?

  • $0.075$ to $1.0$ mm
  • $2.5$ to $5.0$ m/s
  • $400$ MPa (correct)
  • $0.2$ to $1.4$ MPa

    • What is the typical standoff distance used in abrasive water jet cutting (AWJC)?

    <p>Between $1/4$ and $1/2$ of those in WJC</p> Signup and view all the answers

    What is the typical abrasive feed rate used in abrasive water jet cutting (AWJC)?

    <p>About $0.25$ kg/min</p> Signup and view all the answers

    What is the most common type of orifice jewel used in abrasive water jet cutting (AWJC)?

    <p>Sapphire</p> Signup and view all the answers

    What is a disadvantage of Electrochemical Machining (ECM)?

    <p>Complex electrode design</p> Signup and view all the answers

    Which application is NOT listed for Electrochemical Machining (ECM)?

    <p>Grinding metal parts</p> Signup and view all the answers

    What is the main purpose of Electrochemical Deburring (ECD)?

    <p>To round sharp corners on metal parts</p> Signup and view all the answers

    How does Electrochemical Deburring (ECD) differ from Electrochemical Grinding (ECG)?

    <p>ECD has shorter cycle times as less material is removed, ECG has longer cycle times</p> Signup and view all the answers

    What makes Electrochemical Grinding (ECG) different from conventional grinding methods?

    <p>Use of electrically nonconductive bonding material</p> Signup and view all the answers

    Why are cycle times much shorter in Electrochemical Deburring (ECD) compared to Electrochemical Grinding (ECG)?

    <p>ECD removes much less material per cycle</p> Signup and view all the answers

    What type of material is suitable for Electrochemical Machining (ECM)?

    <p>Electrically conductive material</p> Signup and view all the answers

    What is the purpose of the flowing electrolyte in Electrochemical Machining?

    <p>To transport removed material and remove heat</p> Signup and view all the answers

    Which materials are commonly used for electrodes in Electrochemical Machining?

    <p>Copper, brass, and stainless steel</p> Signup and view all the answers

    What voltage range is typically used in Electrochemical Machining?

    <p>5-25 V</p> Signup and view all the answers

    Why is Electrochemical Machining preferred for parts that should not have any thermal damage?

    <p>Because it does not cause any thermal damage to the parts</p> Signup and view all the answers

    In Electrochemical Machining, what function does the tool serve in relation to the workpiece?

    <p>The tool removes material from the workpiece</p> Signup and view all the answers

    Study Notes

    Abrasive Water Jet Cutting (AWJC)

    • Abrasive particles (aluminum oxide, silicon dioxide) are added to the water jet stream.
    • Grit sizes range between 60 and 120 μm.
    • Grits are added to the water stream at about 0.25 kg/min.
    • The orifice jewel may be ruby, sapphire, or diamond, with sapphire being the most common.
    • Nozzle orifice diameter: 0.25 - 0.63 mm, which is slightly larger than in water jet cutting.
    • Water pressures are about the same as in WJC (400 Mpa).
    • Typical standoff distances are between 1/4 and 1/2 of those in WJC.

    Abrasive Jet Machining (AJM)

    • A material removal process caused by the action of a high-velocity stream of gas containing small abrasive particles.
    • Pressure: 0.2 to 1.4 Mpa.
    • Nozzle orifice diameter: 0.075 to 1.0mm.
    • Velocities: 2.5 to 5.0 m/s.
    • Gases: dry air, nitrogen, carbon dioxide, and helium.
    • Typical abrasives: aluminum oxide (for aluminum and brass), silicon carbide (for stainless steel and ceramics), and glass beads (for polishing).
    • Grit sizes are small, 15-40 μm in diameter and must be uniform in size for a given application.

    Advantages of AJM

    • Low cost.
    • Less vibration.
    • No heat is generated in the workpiece.
    • Ability to cut complex holes.
    • No burrs as in conventional machining.
    • Low tool wear.
    • Relatively high metal removal rates for hard and difficult metals.
    • Capable of machining complex parts and hard materials.
    • High production and high tolerances.

    Electrochemical Deburring (ECD)

    • Modification of ECM to remove burrs or round sharp corners on metal parts.
    • The electrolyte flows through the hole to carry away the burr particles.
    • Cycle times are much shorter, typically less than a minute.

    Electrochemical Grinding (ECG)

    • An improved electrochemical grinding wheel electrode consisting of electrically conductive abrasive grains bonded together with nonconductive bonding material.

    Electrochemical Machining Processes

    • Electrical energy is used in combination with chemical reactions to remove material.
    • Reverse of electroplating in that it removes material instead of adding it.
    • Work material must be a conductor.

    Electrochemical Machining (ECM)

    • Material removal from an electrically conductive workpiece using an electrode (tool) in close proximity to the work but separated by a rapidly flowing electrolyte.
    • Material is removed from the anode workpiece (positive pole) and transported to the cathode tool (negative pole) in an electrolyte bath.
    • Electrolyte carries off the material that has been removed from the workpiece.
    • Electrolyte – salt solutions like sodium chloride (NaCl) or sodium nitrate (NaNO3) mixed in water.
    • The flowing electrolyte also serves the function of removing heat and hydrogen bubbles created in the chemical reactions of the process.
    • Electrode materials: Cu, brass, or stainless steel.
    • Tool has the inverse shape of the part.
    • Tool size and shape must allow for the gap.
    • Die is gradually lowered into workpiece.
    • Low voltage (5-25 V) and very high current (700 amps).

    Advantages of ECM

    • Does not cause any thermal damage to the parts.

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    Description

    Learn about Abrasive Water Jet Cutting (AWJC) where abrasive particles are added to a water jet stream. Discover the types of abrasives used, grit sizes, orifice jewel materials, and nozzle orifice diameters.

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