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1, pp 001-006
ABSTRACT
Carbon fiber reinforced polymeris an extremely strong and light fiber-reinforced polymer
composite. It is widely used in advanced technological applications.In the present work, surface
roughness in abrasive waterjet machining of carbon fiber reinforced polymer is studied. Three distinct
regions on machined samples are identified to measure surface roughness. Microscopic features of
machined surfaces are analysed using SEM. Optimization of process parameters is performed using
orthogonal array with the grey relational analysis to minimize the surface roughness in all regions. A
set of machining parameters namely standoff distance, hydraulic pressure, traverse rate, and abrasive
mass flow rate is optimized. Further ANOVA for grey relation grades (GRG) is performed and it is
found that pressure and traverse rate are the most significant parameters in influencing surface
roughness. GRG of optimized set of process parameters is predicted using the results of experimental
analysis. Confirmation tests are carried out to verify the experimental analysis and optimized set of
parameters.
Keywords: Abrasive water jet machining, Surface roughness, Carbon fiber reinforced polymer,
Process parameters.
1. Introduction
001
SME
Value
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Unit
--
570
MPa
Density
Young's Modulus - Longitudinal
1.5
70
g cm-3
GPa
Level
4
--
200
220
240
260
SOD
(mm)
P
(MPa)
TR
(mm/min)
AMFR
(gm/min)
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
1.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
2.0
200
200
200
200
220
220
220
220
240
240
240
240
260
260
260
260
200
200
200
200
220
220
220
220
240
240
240
240
260
260
260
260
50
100
150
200
50
100
150
200
50
100
150
200
50
100
150
200
50
100
150
200
100
50
150
200
50
100
150
200
50
100
150
200
600
700
800
900
600
700
800
900
700
600
900
800
700
600
900
800
900
800
700
600
900
900
700
600
800
900
600
700
800
900
600
700
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Level
3
--
P (MPa)
Expt.
no.
Level
2
2.0
Property
SOD (mm)
Level
1
1.0
3.
TR (mm/min)
50
100
150
200
4.
AMFR (g/min)
600
700
800
900
SOD- Stand-off distance, P- Jet pressure, TR- Traverse rate,
AMFR- Abrasive mass flow rate
2. Experimental Work
Parameter
002
SME
and
taken
into
Level 1
Level 2
Level 3
Level 4
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Average GRGs
P
TR
0.485499
0.756669
0.627501
0.673733
0.676611
0.561303
0.690391
0.488297
AMFR
0.601149
0.597512
0.654087
0.627253
SOD
0.597848
0.642153
---
GRG
0.526910
0.524426
0.475369
0.402484
0.580916
0.550760
0.501252
0.517765
0.773809
0.762799
0.572500
0.552200
0.947600
0.711810
0.645927
0.519044
0.535761
0.501456
0.436864
0.480719
0.874727
0.869749
0.618654
0.506184
0.882057
0.681976
0.705127
0.402418
0.931568
0.786885
0.534730
0.445562
003
SME
(d)
(a)
(e)
Fig. 2 (a) GRG v/s SOD, (b) GRG v/s P, (c) GRG v/s
TR, (d) GRG v/s AMFR, (e) Combined effect of all
process parameters on GRG
(b)
(c)
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004
SME
SS
DF
MS
Fcal
Ftable
(0.05)
4.32
3.47
3.47
3.47
SOD
0.016
1
0.016
1.797
I
P
0.210
3
0.070
8.031
S
TR
0.339
3
0.113
12.928
S
AMFR
0.017
3
0.006
0.634
I
error
0.183
21
0.009
Total
0.765
31
SS- sum of squares; DF- degree of freedom; MS- mean square; F- F
ratio; R- Remark; S- Significant, I- Insignificant
(a)
(b)
1
2
3
4
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005
SME
6. Conclusion
An experimental study of AWJM of CFRP has
been presented. Three distinct regions are observed on
machined surfaces i.e. top region (damaged at jet entry),
middle region (smooth finish) and bottom region (rough
and uncut at jet exit).It is found that pressure and
traverse rate are the most significant factor to control
surface roughness. It is observed that surface roughness
decreases with increase in pressure. Hence with higher
pressure, minimum surface roughness is achieved. An
increase in the traverse speed causes a constant increase
in the surface roughness. The experimental results for
the optimal parameters show that there is considerable
improvement in the surface finish. The confirmation
testresults show that, CFRP material can be effectively
cut by AWJM with minimum surface roughness.
References
1.
2.
3.
5.
6.
7.
8.
9.
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4.
006
SME