Abrasive Water Jet Machining:

Advancements and Future Prospects

BT21MEC109 LEENA OZA

Course Co-ordinator: Dr. TVK Gupta BT21MEC049 RAJ SAHAY
CONTENT
• Introduction
• Working of AWJM
• Application of AWJM in aerospace industry
• Advancements in AWJM in past 5-6 years
• Research Paper
• Scope of improvements
• Conclusion
• Bibliography
Introduction to
Abrasive Water Jet
Machining
1. High-Pressure Water 2. Abrasive Material
Jet
A high-pressure water jet is directed at An abrasive material, such as garnet or
the workpiece, creating a narrow, aluminum oxide, is mixed with the water jet.
focused stream of water.

3. Cutting Process 4. Important Process

The abrasive particles are propelled by
Parameters
Parameters such as stand-off distance
the water jet, eroding the material and (SOD), tool feed rate (TFR), play a crucial
creating a cut. role in optimizing surface finish, kerf width,
and material removal rate.
Working principle of AWJM
PROCESS
1. A pump pressurizes water to extremely high
levels (up to 600 MPa) and directs it through a
small-diameter nozzle to create a high-velocity
water stream.

2. Abrasive particles (e.g., garnet) are mixed with

the water stream in a mixing chamber. The
abrasive-laden stream gains kinetic energy,
enhancing its cutting power.

3. The high-energy abrasive water jet strikes the

workpiece at high speed, eroding the material
through micro-cutting and impact.

4. The process is a cold cutting method, ensuring

no heat-affected zones or material
deformation, making it suitable for heat-
sensitive and intricate parts
Application of AWJM PROCESS
 Cutting Titanium Alloy (Ti-6Al-4V)
o Material: This alloy is commonly used in aerospace for turbine blades due to high strength and resistance to
extreme conditions.

o Cutting Process: The water jet operates at pressures up to 4000 bar accelerating the abrasive particles. They
impact the titanium surface at supersonic speeds and remove material layer by layer through erosion. The
process avoids heat affected zones , which helps in maintaining the properties of titanium and preventing
thermal deformations.

o Parameters: Abrasive flow rate should be optimal (300g/min) to maintain surface finish. Maintaining surface
distance between nozzle and workpiece to minimize kerf taper. Slower speeds improve precision but reduces
productivity.
Application of AWJM PROCESS
Application of AWJM PROCESS
 Challenges:
o High speed abrasives cause wear over time affecting precision of cutting.
o Kerf taper: Uneven material removal can result in tapered cuts.
o Abrasive waste: Improper disposal of used abrasives can impact the environment.

 Improvements:
o Nozzle material: Using tungsten carbide or diamond coated nozzles increases lifespan.
o Automation: Real-time monitoring of parameters like jet pressure and abrasive feed rate.
o Recycling abrasives: Developing systems to collect and reuse abrasive particles reduce costs and waste.
Advancements in Abrasive Water Jet
Machining Technology (2018-2023)
1 2 3

Enhanced Precision and Versatility Application of Advanced Optimization Hybrid Approaches

The introduction of 5axis and 6axis Techniques Hybrid machining techniques
AWJM systems has enabled the Evolutionary algorithms like Particle combining AWJM with other
machining of complex geometries and Swarm Optimization (PSO), Simulated methods, such as additive
3D surfaces with high precision. These Annealing (SA), and Nonlinear Least manufacturing and laser machining,
systems are particularly beneficial for Square Error (LSE) have been integrated have been developed. These
aerospace and automotive industries, into AWJM to optimize parameters such approaches expand the range of
where intricate designs are common​. as tool feed rate, and standoff distance. machinable materials and improve
overall efficiency
Determination and Prediction of Surface and Kerf
Properties in Abrasive Water Jet Machining of Fe-
Cr-C Based Hard Facing Wear Plates
Material Details
• Hard facing Layer: Fe-Cr-C alloy for wear resistance.
• Substrate: St37 steel for machinability.
Experimental Parameters
• MAD (Material Alignment Direction): Steel or hard facing layer facing the jet.
• Abrasive Mass Flow Rate: 200–335 g/min.
• Traverse Speed: 40–60 mm/min.
Measurements:
• Surface quality (surface roughness).
• Kerf properties (kerf taper angle, kerf widths).
Parameter Steel Facing First Hardfacing Facing First
Surface Roughness (µm) 2.5 4.0
Kerf Taper Angle (°) 1.3 2.1
Optimization Requirement Moderate High
Parameter Observation Key Findings
Smoothest when steel layer faces first (Ra ~2.5 MAD contributed ~71% to surface roughness
µm). variation.
Surface Roughness Rougher when hard facing layer faces first (Ra ~4.0
(Ra) µm). Abrasive flow rate had a moderate influence
(~8%).
Lower traverse speeds improved roughness.
Hard facing first MAD increased taper angle to
Kerf Taper Angle (Ta) Smaller taper angle with steel facing MAD (1.3°).
~2.1° due to energy loss in the harder layer.
Hard facing layer exhibited severe wear
Morphological Steel layer showed smoother cuts and fewer
zones, striation marks, and energy dissipation
Analysis striation patterns.
effects.
Energy dissipates rapidly within the hard
Hard facing layer: Dominance of micro-ploughing
Wear Patterns facing layer, reducing jet effectiveness deeper
and lip formations.
into the material.
Hard facing first MAD caused earlier energy
Transition from steel to hard facing retained more
Energy Absorption dissipation, leading to uneven cuts and higher
energy for effective cutting.
roughness.
Best performance for hard facing first MAD Abrasive flow rate ≥265 g/min and traverse
Optimization Insights
achieved with: speed of 40 mm/min.
Statistical models reduced defects and improved
machining outcomes.
Scope of improvement
• Process optimization using AI and Machine Learning: These models can be used to optimize parameters like
abrasive flow rate, standoff distance and traverse speed which increases precision and consistency.
• Enhanced Nozzle Designs: Innovations in nozzle materials (e.g. Diamond coated etc.) extend tool life and
maintain accuracy by reducing wear.
• Multi-Axis and Robotic Systems: 5-axis and robotic a WJM system offer greater flexibility, enabling complex
3D cutting in aerospace and medical fields
• Advanced simulation tools: Improved computational fluid dynamics models enable accurate prediction of
erosion patterns, optimizing cutting paths for complex geometries.
• Ice Jet Machining: A sustainable variant using ice particles instead of abrasives, which reduces the
environmental impact while maintaining cutting efficiency. This is particularly effective for cleaning and
deburring.
• Noise and vibration reduction: Advanced designs reduce operational noise and vibration, ensuring safer and
more efficient machining.
Conclusion
• Abrasive Water Jet Machining (AWJM) has emerged as a versatile, precise, and eco-friendly process suitable
for cutting a wide range of materials, including metals, composites, and ceramics.
• Its cold cutting nature eliminates heat-affected zones, preserving material integrity, which is crucial for
aerospace and medical applications.
• Recent advancements in AI integration, multi-axis systems, cryogenic assistance, and nozzle design
enhancements have significantly improved its efficiency and precision.
• Future developments focus on automation, sustainable practices, and hybrid techniques, making AWJM a
critical tool in modern manufacturing.
Bibliography
1. Real-Time Monitoring and Automation:
Engineering.com - An Engineer's Guide to Waterjet Cutting
https://www.engineering.com
2. Mustafa Armağan, Aziz Armağan Arıcı, determination and prediction of surface and kerf
properties in abrasive water jet machining of Fe-Cr-C based hard facing wear plates, journal of
Manufacturing Processes, Volume 117, 2024
3. Sustainability Improvements:
MDPI - Advances and Trends in Non-Conventional Machining
https://www.mdpi.com
4. Advanced Nozzle Designs and Multi-Axis Cutting:
MDPI - Research Progress in Abrasive Water Jet Technology
https://www.mdpi.com
5. Abrasive Enhancements:
Flow Waterjet - AWJM Technology Overview
https://www.flowwaterjet.com