WATER JET MACHINE PROCESS : Working of abrasive water Jet machining process (animation).

ADTW Study

30 Oct 202007:17

Summary

TLDRThe video script delves into the water jet machining process, a versatile non-conventional technique that utilizes high-velocity water jets for cutting materials. It can be used for both soft materials like plastic and rubber, and hard materials such as metals and granite with the addition of abrasive particles. The script covers the working principle, construction, operation, advantages, and disadvantages of water jet machining, highlighting its precision, cleanliness, and environmental friendliness. Applications range from automotive to aerospace industries, and it's also used for paint removal and stress peening. The script provides a comprehensive guide for those interested in this efficient and eco-friendly machining method.

Takeaways

💧 Water jet machining uses a high-velocity jet of water to cut materials, and is also known as water jet cutting.
🔨 For cutting harder materials, abrasive water jet machining is used, which mixes abrasive particles like garnet or aluminium oxide with water.
🏗️ The setup for water jet machining includes a water reservoir, hydraulic pump, intensifier, accumulator, control valve, flow regulator, mixing chamber, and nozzle.
🚀 The hydraulic intensifier increases water pressure from around 5 bars to 3000-4000 bars, which is crucial for the cutting process.
🔄 The accumulator helps to maintain a consistent high pressure by storing and supplying pressurized water as needed.
💦 The control valve and flow regulator manage the pressure and flow of the water jet, ensuring precision in cutting.
🔩 The nozzle, often made of ruby or diamond, converts the high pressure of water into a high-velocity stream for cutting.
🗑️ The drain and catcher system separates debris and particles from the water after machining, allowing for water reuse.
🛠️ Water jet machining is capable of producing complex cuts and is clean, dust-free, and has low operating costs due to the lack of moving parts.
♻️ It is environmentally friendly, producing no pollution or toxic byproducts, and can achieve high precision with tolerances of ±0.005 inches.
🚫 Disadvantages include the inability to machine very thick materials and the high initial cost of the equipment.

Q & A

What is water jet machining also known as?
-Water jet machining is also known as water jet cutting.
What type of materials can be cut using water jet machining?
-Water jet machining can cut both softer materials like plastic, rubber, or wood, and harder materials like metals or granite when an abrasive material is mixed with the water.
What is the term used when an abrasive material is mixed with water in the machining process?
-When an abrasive material is mixed with water for the machining process, it is called abrasive water jet machining.
What are the common abrasive particles used in abrasive water jet machining?
-The most commonly used abrasive particles in abrasive water jet machining are garnet and aluminium oxide, although sand and glass beads are also used.
What is the function of the abrasive particles in water jet machining?
-The function of the abrasive particles is to enhance the cutting ability of the water jet.
What are the main components of a water jet machining setup?
-The main components of a water jet machining setup include a water reservoir, hydraulic pump, booster, hydraulic intensifier, accumulator, control valve, flow regulator or valve, mixing chamber or tube, nozzle, and a drain and catcher system.
How does the hydraulic intensifier increase the pressure of water?
-The hydraulic intensifier increases the pressure of water from about four to three thousand to four thousand bar.
What is the purpose of the accumulator in water jet machining?
-The accumulator stores high pressurized water temporarily and supplies it when a large amount of pressure energy is required, helping to eliminate pressure fluctuation during the machining process.
What is the typical velocity of the water jet that comes out of the nozzle?
-The typical velocity of the water jet coming out of the nozzle is about one thousand meters per second.
What are some of the advantages of water jet machining?
-Advantages of water jet machining include the ability to produce complex cuts, a clean and dust-free machining area, low operating and maintenance costs, negligible thermal damage to the workpiece, the ability to cut a wide range of materials, being environmentally friendly, and high precision machining.
What are some of the disadvantages of water jet machining?
-Disadvantages of water jet machining include the inability to machine very thick materials and the high initial cost of the equipment.
In which industries is water jet machining commonly used?
-Water jet machining is commonly used in various industries such as mining, automotive, and aerospace for cutting, shaping, and other operations.
What are some of the materials commonly machined by water jet?
-Materials commonly machined by water jet include rubber, textiles, plastics, foam, leather, composites, tile, stone, glass, paper, and more.
What are some additional applications of high pressure water jet besides the machining process?
-Besides the machining process, high pressure water jet is used in paint removal, surgery, cleaning, and peening to remove residual stress.

Outlines

00:00

💧 Introduction to Water Jet Machining

This paragraph introduces water jet machining, a non-conventional machining process that uses a high-velocity jet of water to remove material from a workpiece. It can be used on both soft materials like plastic and rubber, and harder materials like metal and granite, with the latter requiring the addition of abrasive particles to enhance cutting ability. The video script outlines the topics to be covered, including the working principle, construction, working process, applications, advantages, and disadvantages of water jet machining. The principle is based on water erosion, and the setup includes components like a water reservoir, hydraulic pump, intensifier, accumulator, control valve, mixing chamber, nozzle, and a drain and catcher system. The paragraph concludes with an invitation to subscribe to the channel for updates.

05:03

🛠 Advantages and Applications of Water Jet Machining

This paragraph delves into the advantages of water jet machining, such as its ability to produce complex cuts, maintain a clean machining area, have low operating costs due to the lack of moving parts, and cause minimal thermal damage to the workpiece. It also highlights the environmental benefits and precision capabilities of the process. The disadvantages mentioned include the inability to machine very thick materials and the high initial cost of the equipment. The applications of water jet machining span various industries, including mining, automotive, and aerospace, for cutting, shaping, and other operations. The paragraph lists materials commonly machined by water jet, such as rubber, textiles, plastics, and glass, and notes that abrasive water jet machining is used for hard and difficult-to-machine materials like steel plates and ceramics. It also mentions other uses of high-pressure water jets, such as paint removal and stress peening, and concludes with an encouragement to like and subscribe to the channel for more content.

Mindmap

Keywords

💡Water Jet Machining

Water Jet Machining is a non-conventional machining process that uses a high-velocity jet of water to remove material from the surface of a workpiece. It is central to the video's theme as it explains the process and its various aspects. The script describes how it can cut both softer materials like plastic and harder materials like metals when combined with abrasives.

💡Abrasive Water Jet Machining

Abrasive Water Jet Machining is a specific type of water jet machining where abrasive particles are mixed with water to enhance the cutting ability, allowing it to cut harder materials such as metals and granite. The script mentions garnet and aluminum oxide as common abrasives, highlighting this concept's importance in expanding the capabilities of water jet technology.

💡Hydraulic Pump

A hydraulic pump is used in the water jet machining setup to circulate water from the storage tank during the machining process. It plays a crucial role in maintaining the water flow necessary for the high-pressure operation, as indicated in the script where it delivers water to the intensifier at low pressure.

💡Intensifier

An intensifier is a component in the water jet machining setup that significantly increases the water pressure, from the pump's low pressure to a very high pressure of up to 3000 to 4000 bar. It is essential for achieving the high-velocity water jet required for effective cutting, as detailed in the script.

💡Accumulator

An accumulator is used to store high-pressure water temporarily and supply it when needed, helping to eliminate pressure fluctuations during the machining process. It ensures a consistent performance in water jet machining, as explained in the script.

💡Control Valve

A control valve is responsible for managing the pressure and direction of the water jet flow. It is a critical component in directing the high-velocity water stream accurately onto the workpiece, as mentioned in the script.

💡Mixing Chamber

The mixing chamber is a vacuum chamber where the abrasive particles are mixed with the water. It is vital for the abrasive water jet machining process, as it ensures the even distribution of abrasives in the water stream, enhancing the cutting capability, as described in the script.

💡Nozzle

The nozzle is a critical component used to convert the pressure energy of water into kinetic energy, creating a high-velocity water jet. The script specifies that the nozzle's tip is made of ruby or diamond to prevent erosion, emphasizing its importance in the water jet machining process.

💡Drain and Catcher System

The drain and catcher system is responsible for separating debris and machined particles from the water after the machining process. It removes metal particles and other unwanted materials, sending the water back to the reservoir for reuse, as outlined in the script.

💡Advantages

The advantages of water jet machining listed in the script include its ability to produce complex cuts, maintain a clean machining area, have low operating costs, cause negligible thermal damage, cut a wide range of materials, be environmentally friendly, and achieve high precision. These advantages highlight the benefits and versatility of water jet machining.

💡Disadvantages

The script mentions that water jet machining cannot machine very thick materials and has a high initial cost. These disadvantages provide a balanced view of the technology, indicating its limitations despite its numerous advantages.

💡Applications

Water jet machining has a wide range of applications across various industries such as mining, automotive, and aerospace for cutting, shaping, and other operations. The script provides examples of materials commonly machined by water jet, including rubber, textiles, plastics, foam, leather, composites, tile, stone, glass, paper, and more, showcasing its diverse uses.

Highlights

Water jet machining, also known as water jet cutting, is a non-conventional machining process using a high-velocity water jet to remove material from the workpiece.

The process can cut both softer materials like plastic, rubber, and wood, as well as harder materials like metals and granite by mixing an abrasive material with water.

When abrasive material is mixed in water, the process is termed as abrasive water jet machining.

Garnet and aluminum oxide are the most commonly used abrasive particles, with sand and glass beads also being utilized.

The construction of a water jet machining setup includes a water reservoir, hydraulic pump, intensifier, accumulator, control valve, flow regulator, mixing chamber, and nozzle.

The hydraulic intensifier increases water pressure from about 5 bars to 3000 to 4000 bars.

The accumulator stores high-pressure water to provide a consistent pressure supply during machining.

The nozzle converts the pressure energy of water into a high-velocity water jet, with the tip made of ruby or diamond to prevent erosion.

A drain and catcher system separates debris and machined particles from the water, recycling it back to the reservoir.

Water jet machining is capable of producing complex and intricate cuts in materials.

The machining area remains clean and dust-free due to the nature of the process.

Operating and maintenance costs are low as there are no moving parts involved in the process.

Thermal damage to the workpiece is negligible due to the absence of heat generation.

Water jet machining is environmentally friendly as it does not create pollution or toxic byproducts.

High precision can be achieved with tolerances in the order of plus or minus 0.005 inch.

One of the disadvantages is the inability to machine very thick materials.

The initial cost of water jet machining equipment is high.

Water jet machining is used in industries such as mining, automotive, and aerospace for cutting, shaping, and other operations.

Common materials machined by water jet include rubber, textiles, plastics, foam, leather, composites, tile, stone, glass, paper, and more.

High-pressure water jets are also used for paint removal, surgery, cleaning, and peening to remove residual stress.

Abrasive water jet machining can be used for drilling, pocket milling, and turning operations.