GOVERNMENT POLYTECHNIC COLLEGE

THOOTHUKUDI- 628 008

PROJECT REPORT

ON

FABRICATION OF MULTI NOZZLE ABRASIVE WATER JET

MACHINING

Under the Guidance of

Thiru.B.RAMESHKUMAR, B.E, MBA,

Submitted by

SL.NO REG. NO NAME OF THE STUDENT

1 12800490 G. SELVAKUMAR

2 12800491 I. SELVAM

3 10800430 M. THANGAMANI

4 10800433 S. VIGNESH

Submitted in partial fulfillment for the award of Diploma In Mechanical

Engineering of State Board of Technical Education, Tamilnadu.

DEPARTMENT OF MECHANICAL ENGINEERING ACADAMIC YEAR 2014-2015

GOVERNMENT POLYTECHNIC COLLEGE THOOTHUKUDI - 628 008

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 Head of the Department

Thiru.B.RAMESH KUMAR, B.E, MBA Thiru.P.MUTHURASU, M.E,MIE,P.hd Submitted for Board Practical Examination held on_______ ____________

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.

It evolves out the concept of group activity. It further

promotes co-operation, co-ordination and ability of individual.

That is a way applying the above concepts, we have carry

out our project is fabrication of solar power hack saw machine.

We ourselves planned organized and executed to bring

our project as successful one.

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.

The needed for development confidence in

mind of students project work is introduced as a part curricular activities. We

called abrasive water jet machining. This has really made us sense of thorough of

the project, which made an inspiration in or mind.

In this report, the construction and working

principle or given in elaborate to understand easily. This project has been

beneficial to us as we gained much practical knowledge. We have also clarified

many doubts come across during the development of the project.

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

High velocity abrasive water jet can machine thin

sheets / foils of aluminum, leather, textile, frozen, food etc.,

In pure AWJM, commercially pure water (tap

water) is used for machining purpose. However as the high velocity abrasive water

jet is discharged from the orifice, the jet tends to entrain atmosphere air and flares

out decreasing its cutting ability, glass beads are added to the abrasive water jet to

enhance its cutting ability by many folds. AWJM are mainly of two types

entertained and suspended type as mentioned earlier.

Most water jet cutting theories explain water jet

cutting as a form of micro erosion as descried here. Abrasive Water jet cutting

works by forcing a large volume of water through a small orifice in the nozzle. The

constant volume of water traveling through a reduced cross sectional area causes the

practice to rapidly accelerate.

This accelerated stream leaving the nozzle

impacts the material to be cut. The extreme pressure of the accelerated water

particles contacts a small area of the wok piece. In this small area the work piece

develops small cracks due to stream impact. The abrasive water jet washes away

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

intensifier pump or the newer, simpler crankshaft-driven triplex plunger pump.

Crankshaft pumps are inherently more efficient than intensifier pumps because they

do not require a power-robbing hydraulic system. The crankshaft drive is a purely

mechanical direct-drive system with minimal friction losses and so efficiencies

between 85% and 90% are typical. This means that 85% or more of the electric

power supplied to the drive motor can actually be delivered to the cutting nozzle,

compared to the typical 65% or less of an intensifier.

Accumulator: It is used for temporarily storing the pressurized water. It is connected

to the flow regulator through a control valve.

Control Valve: It controls the direction and pressure of pressurized water that is to

be supplied to the nozzle.

Flow regulator: It is used to regulate the flow of water. Abrasive Sand: This is the medium used to mix with water to blast the metals

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 : 0.5 Hp Voltage : 220V Watt : 7 watts

2. Reservoir tank:

Capacity : 20 liter

3. Flow Control Valve :

Size : 1 Ball Valve

4. Nozzle :

Size : 4 mm Pressure : 8 -10 Kpa

Size : 5 mm Pressure : 10 -12 Kpa

Size : 6 mm Pressure : 10 -15 Kpa

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.

One of the most versatile machining processes.

Compliments other technologies such as milling laser, EDM, plasma and

routers.

True cold cutting process no HAZ, mechanical stresses or operator and

environmental hazards.

Not limited to machining food industry applications

Pure AWJ Cutting :

Pure cuts soft materials corrugated cardboard, disposable diapers, tissue

papers, automotive interiors.

Very thin stream ( 4.0 6.0 dia )

TYPE OF MACHINING PROCESS

The general grouping of some of the typical non traditional processes are

shown below:

1. Mechanical process

- USM - Ultrasonic Machining

- AJM Abrasive Jet Machining

- WJM and AWJM

2. Thermal process

- EBM Electron Beam Machining

- LBM Laser Beam Machining

- PAM Plasma Arc Machining

- EDM and WEDM

3. Electrical process

- ECM Electro Chemical Machining

- EDG Electrical Discharge Grinding

- EJD - Electro Jet Drilling

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.

2D LAYOUT OF ABRASIVE WATER JET MACHINING

A diagram of a Abrasive water jet cutter

1. High pressure water inlet

2. Jewel ( ruby or diamond )

3. Abrasive ( garnet )

4. Mixing Tube

5. Guard

6. Cutting water Jet.

7. Cut material

WATER TANK

4 5 6

WORK PIECE

FLOW CONTROL1 VALVE

1VALVE

ABRASIVE RESERVOIR

MOTOR-PUMP

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:

Depending on whether a contour is to be simply cut out of the material, or the

piece should be in the top quality possible, the unit cost can go up by even five

times.

BILL OF MATERIALS

Sl. No COMPONENTS MATERIALS QTY

1.

WATER PUMP. ( Self priming - 1/2 HP)

C.I

1 No.

2.

COIL WINDING

COPPER

AS PER REQIREMENT.

3.

MULTI DIMENSIONAL

NOZZLE

M.S

3 Nos.

4. SLEEVE M.S 1 No.

5.

CASING

M.S

1 No.

6.

ABRASIVE

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.

12.

SECTION HOSE

PLASTIC

AS PER REQIREMENT.

13.

BOLT & NUT

M.S.

2 Nos.

14.

WATER TANK.

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 - Rs. 350 /- 2. Fabrication Cost - Rs. 1500 /- 3. Painting Cost - Rs. 100 /-

TOTAL - Rs. 1950 /-

Direct Labour Cost:

1. Manufacturing Cost - Rs. 650 /- 2. Assemble Cost - Rs. 350 /- TOTAL - Rs. 1000 /- Prime Cost: Direct material cost + Direct labour cost = Rs. 2100 /- + Rs. 1000 /-

TOTAL - Rs.2950 /-

Over head cost: % of prime cost TOTAL - Rs. 950 /- Total Cost 1. Over head cost + Prime cost = Rs. 2950 /- + 950 /- = Rs. 3900 /- TOTAL - Rs. 3900 /- (Rupees three thousand nine hundred only)

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.

It also develops co operation, co ordination and awareness of their

own individual skills, etc,. The project also lays emphasis to team work. It

enlightens also aims at individual commitment towards to work.

Thus, we the students, here by conclude by insisting that project work

builds up confidence in an individuals personality. Thus all above features Turned

out Multi Nozzle Abrasive Water Jet Machining as a superior and successful

project.

BIBLIOGRAPHY TEXT BOOK:

TITLE: ABRASIVE WATER JET CUTTING: TECHNOLOGY AND INDUSTRIAL APPLICATION. AUTHOR: RICHARD KENDALL MILLER. TITLE: PRINCIPLES OF ABRASIVE WATER JET MACHINING. AUTHOR: ANDRAS W. MOMBER. TITLE : JET CUTTING TECHNOLOGY. AUTHOR: D. SAUNDERS. TITLE : HIGH VELOCITY LIQUID JET AUTHOR: FRANZ, NORMAN. C WEBSITE:

http://auto.howstuffworks.com http://www.google.com http://www.wikipedia.com

http://auto.howstuffworks.comhttp://www.google.comhttp://www.wikipedia.com