The document discusses abrasive waterjet machining (AWJM), a non-conventional machining process. It provides a brief history of AWJM, describing how abrasives were added to waterjets in the 1970s to allow cutting of harder materials. The key components of an AWJM system are described, including water reservoirs, intensifier pumps to generate ultra-high water pressures, multi-axis motion systems, and abrasive-fed nozzles. Advantages are clean cutting with minimal heat impact and ability to cut a wide range of materials efficiently. Disadvantages include high operating costs for hard materials and inability to cut very thick parts. The document outlines applications and provides comparisons to other non-conventional machining methods.

2. Non-conventional machining
processes
• Electric Discharge Machining.
• Chemical Machining.
• Abrasives Water Jet Machining.
• Electrochemical Machining.
• Plasma Machining

3. History
 Dr. Franz in 1950’s first studied UHP water cutting for
forestry and wood cutting (pure WJ)
 1979 Dr. Mohamed Hashish added abrasive particles to
increase cutting force and ability to cut hard materials
including steel, glass and concrete (abrasive WJ)
 First commercial use was in automotive industry to cut
glass in 1983
 Soon after, adopted by aerospace industry for cutting
high-strength materials like Inconel, stainless steel and
titanium as well as composites like carbon fiber

4. Introduction Abrasive Waterjet Machining
• Water jet cutter, also known as a water jet or water jet , is an
industrial tool capable of cutting a wide variety of materials
using a very high-pressure jet of water, or a mixture of water
and an abrasive substance
• JET : A rapid stream of liquid or gas forced out of a small
opening.
• The term abrasive jet refers specifically to the use of a mixture
of water and abrasive to cut hard materials such as metal
or granite, while the terms pure water jet and water-only
cutting refer to water jet cutting without the use of added
abrasives, often used for softer materials such as wood or
rubber.

5. Parameters Considered
• Abrasives
• Medium i.e. Water
• Nozzle
(diameter ,material ,operating axis)
• Pressure

6. MACHINE SETUP
• Water reservoir
• Pump
• Intensifier pump
• Nozzle
• Nozzle controlling unit
• Different valves

7. Water Reservoir And Pump
• Reservoir is nothing but water storage. From
which the pump sucks the water
• There are two types of pumps are used the
first one is common pump such as centrifugal
pump. Another one is intensifier pump which
ultra pressure generating pump.

8. Intensifier Pumps:
•Intensifier pump utilize the ”intensification principle”
Hydraulic oil is pressurized to a pressure ,say,3000psi.The oil
pushes against the piston biscuit .
•A plunger with face area of 20 times less than the biscuit
pushes against the water.
•Therefore, the 3,000psi oil pressure “intensified”20 times,
yielding up to 60,000psi water pressure. The intensification
principle varies the
area component pressure
equation to intensify, or
increase,
the pressure

9. Nozzle
• It is discharge point of water and abrasive mixture . the
nozzle has small diameter for opening the diameter must
not be more than 1,32mm.
• The discharging water has speed upto 4000kmph.nozzle
has two inlet ports one for high pressure oil and another
one for abrasives. There is separate mechanism to feed
the nozzle that is it is not controlled by manually
• Only by the CNC it should be controlled.
• The material of nozzle is Tungsten carbide or sffire.the
material should be hard and the particles must be tightly
bonded with each other. The material should be
chemically inactive

10. Nozzles

11. Typical Machining Centre

12. Working Process of abrasive water jet
machining
• There are six main process in Abrasives water jet cutting:
• Uses a high velocity stream of Ultra High Pressure Water 30,000–
90,000 psi (210–620 MPa) which is produced by an intensifier
pump with possible abrasive particles suspended in the stream.
• Is used for machining a large array of materials, including heat-
sensitive, delicate or very hard materials.
• Produces no heat damage to workpiece surface or edges.
• Nozzles are typically made of sintered boride.
• Produces a taper of less than 1 degree on most cuts, which can
be reduced or eliminated entirely by slowing down the cut
process or tilting the jet.
• Distance of nozzle from workpiece affects the size of the kerf and
the removal rate of material. Typical distance is .125 in (3.2 mm).
• Temperature is not as much of a factor

13. Multi Axis Cutting
• With recent advances in control and motion technology, 5-axis
water jet cutting (abrasive and pure) has become a reality.
• Where the normal axes on a water jet are named Y
(back/forth), X (left/right) and Z (up/down), a 5-axis system
will typically add an A axis (angle from perpendicular) and C
axes (rotation around the Z-axis).
• Depending on the cutting head, the maximum cutting angle
for the A axis can be anywhere from 55, 60, or in some cases
even 90 degrees from vertical.
• As such, 5-axis cutting opens up a wide range of applications
that can be machined on a water jet cutting machine

14. Advantages of water jet machining
• Cheaper than other processes.
• Cut virtually any material.
• 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

15. • Unlike machining or grinding, waterjet cutting does not produce
any dust or particles that are harmful if inhaled.
• The kerf width in waterjet cutting is very small, and very little
material is wasted.
• Waterjet cutting can be easily used to produce prototype parts
very efficiently. An operator can program the dimensions of the
part into the control station, and the waterjet will cut the part
out exactly as programmed. This is much faster and cheaper
than drawing detailed prints of a part and then having a
machinist cut the part out.
• Waterjets are much lighter than equivalent laser cutters, and
when mounted on an automated robot. This reduces the
problems of accelerating and decelerating the robot head, as
well as taking less energy.

16. Disadvantages of abrasives water jet
machining
• Abrasives are embedded in the work spaces that have soft
surfaces as like elastomers or soft plastics.
• The tapering of the hole is hampered in its accuracy; this is
due to the flares in abrasive jets.
• The stray cut is difficult to avoid.
• Dust collection system is a basic need to prevent the
atmospheric pollution and health hazards.
• The life of the nozzle is very limited upto 300hours
approximately.
• The abrasive powder is restricted be reused because the
sharp edges may worn out there is a chance to clog small
particles in the nozzle.
• The short standoff distance may damage the nozzle when
they are used for cutting.

17. • One of the main disadvantages of abrasive waterjet cutting is that a
limited number of materials can be cut economically. While it is
possible to cut tool steels, and other hard materials, the cutting rate
has to be greatly reduced, and the time to cut a part can be very long.
Because of this, waterjet cutting can be very costly.
• Another disadvantage is that very thick parts can not be cut with
waterjet cutting and still hold dimensional accuracy. If the part is too
thick, the jet may dissipate.

18. Applications And Materials Machined Using
Abrasive Water Jet Machining
Application
• 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
• Honeycombs
• Metal Matrix Composite
• Ceramic Matrix Composite
• Concrete
• Stone – Granite
• Wood
• Reinforced plastics
• Metal Polymer Laminates
• Glass Fibre Metal
Laminates

19. Comparison Of AWJM With Other Non
Conventional Methods
After plasma cutting
After AWJM After AWJM
After laser cutting

20. Future of AWJM
• Drilling wells
• Drilling for oil
• Radial tunnels

21. conclusion
From all the point mentioned above we can
conclude that the nonconventional machining
process like AJM have bright industrial future
.The AJM has shown that it can do things that
other technologies simply cannot. From
cutting whisper, thin details in stone, glass and
metals; to rapid whole drilling of titanium; for
cutting of food, to the killing of pathogens in
beverages and dips, the waterjet has proven
itself unique.