Performance Analysis of Process Parameters on Machining of Aluminium Composite Panel using AWJM process

Abstract

The recent trends shows that numerous new materials are rapidly emerging and developed. It creates considerable interest in the researcher to search out the optimum combination of machining parameters during machining of these materials using advanced machining processes. Abrasive water jet cutting is a non-traditional machining method that offers a productive alternative to conventional techniques. It uses a fine jet of ultra-high pressure water and abrasive slurry to cut the target material by means of erosion. In order to obtain a product with high surface quality, the abrasive water jet machining process must be precisely controlled. In this work, an experimental investigation is carried out on abrasive water jet machining (AWJM) process for the machining of aluminium composite panel using the Taguchi methodology. Parameters such as transverse speed, standoff distance and mass flow rate are considered to obtain the influence of these parameters on kerf taper angle surface roughness and deamination factor. ANOVA and Regression analysis are performed to identify the impact of process parameters on performance parameters. Keywords: AWJM, Taguchi, ANOVA, Regression, Optimization I. INTRODUCTIONAluminium composite panels are flat panels consisting of two thin coil coated aluminium sheets bonded to a non-aluminium core. It is commonly used material by signage industry for providing artwork piece with better strength and aesthetics. The machining of ACP can be done with traditional as well as non-traditional ways of machining. In the case of traditional machining of ACP, in order to minimize the amount of heat generated and avoid thermal damage to the part, the proper tool geometry and operating conditions must be adopted. Precautions also should be taken to avoid introducing delamination in the work piece by limiting tool wear in order to keep machining forces low and by using back-up material to prevent delamination as the tool exist the work piece. So, Particularly in case of ACP composite if traditional machining is need to be done than, a specially designed tool will be required as well as there is also a need of backup material at the tool exit to avoid the amount of delamination. It will be difficult and costlier for industries. The non-traditional machining of ACP is possible with various machining processes like EDM, LBM, ECM, ECDM and AWJM. The main problem associated with EDM process like deposition of resolidified layer that hampers the surface quality. Tool wear and tool breaking are another major problems combined with this process. The LBM produced surfaces are affected by the transformed microstructure of matrix material due to excessive heat, presence of striation pattern and dross attachment at the bottom. The formation of pits at low voltage due to low current density and formation of streak at low electrolyte flow rate due to low turbulence on the machined surface during ECM is obvious. In AWJM the material removal takes place by means of erosion not by deformation wear. The quality of...