See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/328488542

Optimization of Abrasive Water Jet Machining Process Parameters for

Inconel-825 By Using Grey Taguchi Method

Article · October 2018

DOI: 10.32628/18410IJSRSET

CITATIONS READS

0 92

2 authors:

Kiran Kumar G K Bhavani Sankar C.

Siddartha institute of science and technology, Puttur Siddharth Institute of Engineering & Technoology
6 PUBLICATIONS   3 CITATIONS    3 PUBLICATIONS   1 CITATION   

SEE PROFILE SEE PROFILE

Some of the authors of this publication are also working on these related projects:

Hardness and Impact Test of Duplex Stainless steel-2205 Specimen View project

Abrasive Water Jet Machining Process View project

All content following this page was uploaded by Kiran Kumar G K on 24 October 2018.

The user has requested enhancement of the downloaded file.

 © 2018 IJSRSET | Volume 4 | Issue 10 | Print ISSN: 2395-1990 | Online ISSN : 2394-4099
Themed Section : Engineering and Technology

Optimization of Abrasive Water Jet Machining Process

Parameters for Inconel-825 By Using Grey Taguchi Method
G. K. Kiran Kumar*1, C. Bhavani Sankar2
*1 Department of Mechanical Engineering, Siddartha Institue of Science and Technology, Puttur, India
2Department of Mechanical Engineering, Siddharth Institue of Engineering and Technology, Puttur, India

ABSTRACT

Abrasive Water Jet Machining (AWJM) is a versatile and fastest growing machining process primarily used to
machine hard and difficult to machine materials. This machine is also used to machine soft, thick, light, thin
and fragile materials. It compliments other technologies such as Milling, Laser, EDM etc…. It doesn’t possess
any mechanical stress to operator and environmental hazards. AWJM cut the material accurately unlike any
other machining process. AWJM mainly adopted by aerospace industry for cutting high strength materials and
other composites. It finds most of its applications in machining of gas turbines, rocket motors, space craft,
nuclear power and pumps etc., very thin stream of about 0.004 to 0.010 dia. can be cut and material loss is also
less due to cutting. Standoff distance between mixing tube and work part is typically 2 to 4mm important to
keep to a minimum to get superior surface finish. The objective of this research is to analysis the effect of input
process parameters and to optimize process parameters for achieving optimizing Processes responses such as
Metal Removal Rate(MRR), Surface roughness (Ra), and Kerf width simultaneously while machining on the
nickel-chromium based super alloy INCONEL 825 using AWJM process. It is a precipitation hardened material
and has good creep-rupture strength. It shows good mechanical properties even at high temperatures.
Applications are Intricate shapes can be easily obtained for Aerospace products.
Keywords : AWJM, Material Removal Rate, Surface Roughness, Kerf Width
Nomenclature:
AWJM : Abrasive water jet machine
MRR : material removal rate
DOF : degree of freedom
DOE : Design of experiments

I. INTRODUCTION cutting thin details in stone, glass and metals; to rapid

hole drilling of titanium; to cutting of food, to the
Water jets were introduced in the United States killing of pathogens in beverages and dips, the water
during the 1970’s, and were utilized merely for jet has proven itself unique.
cleaning purposes. As the technology developed to
include abrasive water jets, new applications were Water jet machining is a mechanical energy based
discovered. However, until recently this tool had not non-traditional machining process used to cut and
been used to a great extent in the construction machine soft and non-metallic materials. It involves
industry. The water jet has shown that it can do the use of high velocity water jet to smoothly cut a
things that other technologies simply cannot. From soft work piece. In water jet machining, high velocity

IJSRSET1841054 | Received : 25 Sep 2018 | Accepted : 05 Oct 2018 | September-October-2018 [ 4 (10) : 248-261]
248
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

water jet is allowed to strike a given work piece.

During this process its kinetic energy is converted to
pressure energy. This induces a stress on the work
piece. When this induced stress is high enough,
unwanted particles of the work piece are
automatically removed.

Fig. 2. Abrasive and water mixing

Control Valve: It controls the direction and pressure

of pressurized water that is to be supplied to the
Fig.1. Setup of Abrasive water jet machining process nozzle.
Flow regulator: It is used to regulate the flow of water.
The apparatus of water jet machining consists of the
following components: II. DIFFERENT PHASES OF EXPERIMENTATION

Reservoir: It is used for storing water that is to be To achieve the objectives, present research has been
used in the machining operation. done in four phases
Phase-I
Pump: It pumps the water from the reservoir. High Development of Design of experiment (DOE) as per
pressure intensifier pumps are used to pressurize the ranges of processes variables in AWJM machine.
water as high as 55,000 psi. For the abrasive water jet, Experimentation of AWJM is done on Inconel-825
the operating pressure ranges from 31,000 to 37,000 material as per DOE.Measuring the processes
psi. At this high pressure the flow rate of the water is responses on-line and offline.
reduced greatly. Phase-II
Development of Multi-objective optimization model
Intensifier: It is connected to the pump. It pressurizes by using Grey-taguchi technique.
the water acquired from the pump to a desired level. Determination of optimal setting of AWJM Processes
parameters for processes responses simultaneously.
Accumulator: It is used for temporarily storing the Phase-III
pressurized water. It is connected to the flow Development of mathematical model for MRR,
regulator through a control valve. Surface roughness.
Development of Grey Relational Analysis Traverse
speed, Abrasive flow rate, Standoff distance by using
Grey taguchi analysis.
Phase-IV
Development of multi-objective optimization model
for Orthogonal Array L-25.

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

249
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

Determination of optimal setting of AWJM processes useful for modeling and analysis of problems in
parameters for processes responses simultaneously. which the response is influenced by several variables
and the main aim is to find the correlation between
Methodology (or) Step by step procedure followed in the response and the variables i.e., it can be used for
present work : optimizing the response. In the present study water
pressure, abrasive flow rate, orifice diameter, focusing
nozzle diameter and standoff distance are chosen as
the process parameters and varied at three levels and
the commonly used constant parameters of AWJM.
In Response surface design, a Box-Behnken design
table with 24 experiments was selected.

Genetic Algorithm:
Genetic algorithms have been used in science and
engineering as adaptive algorithms for solving
practical problems and as computational models of
natural evolutionary systems. Genetic Algorithms
(GAs) are adaptive heuristic search algorithm based
on the evolutionary ideas of natural selection and
genetics. As such they represent an intelligent
exploitation of a random search used to solve
optimization problems. Although randomized, GAs
are by no means random, instead they exploit
Fig.3. Flow chart followed in present work historical information to direct the search into the
region of better performance within the search space.
OPTIMIZING TECHNIQUES:
Fuzzy Logics:
Taguchi Technique: Fluffy Logic was started in 1965 by Lotfi A. Zadeh,
Dr. Gene chi Taguchi is a Japanese researcher who educator for software engineering at the University of
spent quite a bit of his expert life examining California in Berkeley. Fundamentally, Fuzzy Logic
approaches to enhance the nature of fabricated items. (FL) is a multivalve rationale that permits middle of
After World War II, the Japanese phone framework the road qualities to be characterized between
was gravely harmed and useless. Taguchi was traditional assessments such as genuine/false, yes/no,
designated as leader of Japan's recently framed high/low, and so forth. Ideas like rather tall or quick
Electrical Communications Laboratories (ECL) of can be defined scientifically and handled by PCs,
Nippon Telephone and Telegraph Company. Quite a keeping in mind the end goal to apply a more human-
bit of his exploration at ECL included building up a like state of mind in the programming of PCs. Fluffy
thorough quality change philosophy that included frameworks are a different option for customary
utilization of the DOE strategy. thoughts of set participation and rationale that has its
Response Surface Methodology: starting points in antiquated Greek reasoning.
Response Surface Methodology (RSM) is a collection
of mathematical and statistical techniques that are

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

250
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

Mat Lab: more horizontal to yield positive data about elements

MATLAB, short for MATrix LABoratory is a and levels.
programming bundle particularly intended for brisk
and simple experimental counts and I/O. It has Analysis phase:
actually several inherent capacities for a wide Analysis phase is the point at which the positive data
assortment of calculations and numerous tool stashes regarding the selected components and levels is
intended for particular examination disciplines, produced dedicated around the past two stages. The
including insights, improvement, arrangement of dissection stage is minimum precarious regarding
fractional differential comparisons, information whether the trial will effectively produce positive
investigation. results. These decisions are made with the help of
various analytical techniques mostly used the analysis
III. EXPERIMENTAL DESIGN METHODOLOGY of variance (ANOVA). The advanced proposition is
the collection of numerical results and numerical
DESIGN OF EXPERIMENT (DOE) TECHNIQUES: techniques for determining and identifying the best
result from a collecting of options without
The Design of an experiment is the synchronous demanding to clearly explain and measure all possible
calculation of two or more variables for their capacity selections.
to influence the resultant normal. To satisfy this in a
successful and accurately appropriate form, the levels There are different techniques for design of
of the components are removed in an energetic experiment techniques are there for design and
method, the results specific test combinations are conducting experiments. These are
observed, and the complete set of results is poor [1] Factorial design
depressed to focus the powerful elements and [2] Response surface methodology
preferred levels, and whether expands or diminishes. [3] Mixture design
[4] Taguchi design
The DOE methodology is separated into three
fundamental stages : TAGUCHI TECHNIQUE :
The Taguchi's system is the standardize methodology
Arranging Phase: for determining the best creation of information to
The arranging stage is most dynamic stage for the test deliver a result of component effects. It is trying to
to give the normal data. An experimenter will learn determine the control variable and levels. The
currently and over the data is in a positive sense and product will be continued on performing at target
negative sense. Positive data is an ID of which regard value in the neighborhood of outer and
variables and which levels lead to improve piece internal variety. The discovering better, more steady
implementation. Negative data is a sign of which summaries, not so much ideal devices. Methodologies
components don't quick change. utilize the immediate inspecting of framework
implementation ordinarily utilizing model and
Conducting phase: exceptionally minimal testing systems. This is expert
Conducting stage is the most supreme stage, when through outline of investigation DOE is importance
the test results are actually collected. On the off of tool for design great value classification on
chance that experimenters are decently arranged and condensation of price. The method proposed a parts
led, the dissection is really much less demanding and of quality relation the quality of cost, not in a

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

251
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

production just to the manufacturing time. The Concept design:

customer complaints and dissatisfaction, the fail Model designing is the development of investigative
product money and time spent by customer. And loss competition technology towards creates products.
of the market share. The procedure knowledge choice and method
proposal choice. In this area could be decrease
fabrication cost and outcomes in high feature
products.

Parameter design:
The design indicates to the determination of control
elements and the variables determination of ultimate
levels for each of the components, control variables
will be in methodology parameters such an item is
practically. The high level performance below ranges
of conditions exits. Control calculates that are to be
located at ultimate levels to increase the quality and
decrease the affect capability to noise in Dimensions
of parts. Noise Factors express to the demand that is
standard in creation. Dimensional variation and
operating Temperature. The design parameter one a
time a first feasible design is finding to be an
approach to design optimization. However, leads to
expense of time for completing the design. Optimize
the design so that it improves quality and reduces cost.

Fig.4. Screenshots of DOE in Minitab software

Phases in Taguchi Technique:
[1].Selection of control factors as per noise factors of
Types of Designs in Taguchi Technique:
main function with number of levels.
Taguchi design follows the four steps:
[2].Selection of the number of tests to be carried out
or sort of Orthogonal Array (OA) in the form of
[1].Robust design
matrix.
[2].Concept design
[3].Selection of noise factor to be optimizes.
[3].Structure design (Parameter design) and
[4].Running the tests as per predesigned orthogonal
[4].Acceptance design (Tolerance design)
array matrix in order.
[5].Foretell the optimum levels of control factors with
Robust design:
their corresponding Response factors.
The design expresses that product and directions
[6].Rerun the tests corresponding to optimum levels
must to be planned so they are in alienable escape
to conform them as optimum levels of control factors.
free and of high quality. Design performance is
insensitive to variation in science and engineering.
Selection of Orthogonal Array (OA):
In Taguchi method Control factors refers to input
parameters for the process, and Response factors

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

252
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

refers to corresponding output parameters for the OA Selection Criterion:

process. The Degree of Freedom (DOF) value for the L 25 OA was selected for carrying out experiments
Overall Mean is 1. DOF for a Control Factor = No. of
Levels – 1 Levels of Process Parameters

For example, there is Control Factors X and Y, with

three levels and the DOF for ‘X’, and ‘Y’ is?
Solution: DOF for ‘X’ or ‘Y’= No. of Levels – 1,
DOF for ‘X’ or ‘Y’= 3-1 = 2.
But, DOF for interaction of ‘X’ and ‘Y’ is,
DOF for ‘XY’ = (No. of Levels in ‘X’ - 1) × (No. of
Levels in ‘Y’ -1)
= (3-1) × (3-1)
DOF for interaction of ‘X’ and ‘Y’ (DOF for ‘XY’) = 4.

WORK PIECE MATERIAL:

INCOLONEL alloy 825 is a nickel-iron-chromium

alloy with additions of molybdenum, copper, and
titanium. The alloy’s chemical composition, given in
Table is designed to provide exceptional resistance to
many corrosive environments. The nickel content is
sufficient for resistance to chloride-ion stress-
corrosion cracking. The nickel, in conjunction with
the molybdenum and copper, also gives outstanding
resistance to reducing environments such as those
containing sulfuric and phosphoric acids. The
molybdenum also aids resistance to pitting and
As per Taguchi technique, the processes parameters crevice corrosion. The alloy’s chromium content
of 5 level design has two degree of freedom (DOF) confers resistance to a variety of oxidizing substances
this gives a total of 5-1=4. 3 parameters are such as nitric acid, nitrates and oxidizing salt. The
considered DOF for three processes variables for this titanium addition serves, with an appropriate heat
research. The condition for selecting OA is the DOFs treatment, to stabilize the alloy against sensitization
for selected OA must be higher than DOFs required to intergranular corrosion.
for experiment is 12 so, the nearest OA available for The resistance of INCOLONEL alloys 825 to general
satisfying the condition of selecting OA is L25 have and localized corrosion under diverse conditions
12 DOF’s. The selected L25 OA in terms of coded gives the alloy broad usefulness.
factors has been given in table 5.2.
DOF for a Control Factor = No. of Levels – 1
DOF for A = 5-1 = 4
Total DOF = 12

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

253
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

MACHINE DETAILS :

Description Abrasive Water

Jet Machining
Controlling of CNC
Machine
Voltage 415 V
Frequency 50 Hz
Phases 3
Power 547 W
Current 1.8 A
Table size 3 * 3 * 1.5
Application:
Travel X-axis – 3000mm,
[1].Chemical processing, acid production
Y-axis – 3000mm,
[2].Pollution control, oil and gas recovery
Z-axis – 260mm
and .Pickling operations
Nozzle diameter 1.1 mm
[3].Nuclear fuel reprocessing, and handling of
radioactive wastes Abrasive type Garnet
Abrasive size 80 Mesh
Magnification:
Orifice diameter 0.35 mm
The micro structure of INCONEL-825 seen with
magnifying lens as below Focussing tube 8 mm
diameter
Water pressure 3500 bars
Water flow rate 3.5 litre/min
Impact angle 90 degrees
Nozzle Length 80 mm

IV. MEASUREMENT OF EXPERIMENTAL

PARAMETERS

The discussions related to the measurement of

Abrasive Water Jet Machining experimental
processes parameters e.g. Metal Removal Rate (MRR)
and Kerf width, Surface roughness (Ra) are presented
in the following subsections.

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

254
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

Mechanism and Evaluation of Metal Removal Rate Mechanism and Evaluation of Surface roughness (Ra):
(MRR): In this work the surface roughness is measured
by Mitutoyo surftest SJ-201P
Metal Removal Rate (MRR) is the rate at which the
material is removed from the work piece. The MRR is
defined as the ratio of the amount of metal removed
from the work piece in mm3 to time taken for
machining in min.

MRR=

Where, W = Va - v Fig 6. Mitutoyo surftest SJ-201P instrument

Va= volume of machined specimen on the work piece.
v = volume of cut piece from the specimen. Before machining:
Here we get MRR in terms of mm3/min. To find out The actual weight of the super alloy after purchasing
the MRR in terms of gm/min, the value should be was found out to be 984.94gm.
multiplied with the density of the material chosen.
After machining:
Mechanism and Evaluation of Kerf width: The weight of the super alloy (without 25 specimens)
Kerf width is defined as the width of the material that and the weight of the 25 specimens and the amount
is removed by a cutting process. of metal removed during machining calculated from
Kerf width = metal removal rate combinely turned out to be
Where, S1 = side of the machined specimen on the 991gm which is quiet near to the original weight of
work piece. the super alloy INCONEL-825 i.e., 984.94gm. Hence
S2 = side of the cut piece from the specimen. it is proven that AWJM is a precise and accurate
machine.

Fig.5. Measurement of width in vernier

calliper
V. RESULTS AND DISCUSSIONS

This research analysis have been done by using Mini tab software and by using Grey-Taguchi technique.
Taguchi analysis is suitable for optimizing process parameters for single objective only, but in this chapter

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

255
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

we require to optimize process parameters for multi responses, so Grey-Taguchi technique is employed for
optimizing process parameters to get maximizing Metal Removal Rate, minimum Kerf Width and Surface
Roughness simultaneously during Abrasive water jet machining (AWJM) process

TABLE.1. Taguchi’s L25 Orthogonal Array with Experimental Results

TRANSVERSE ABRASIVE
STAND OFF Kerf Surface
S.NO SPEED FLOW RATE MRR
DISTANCE (mm) Width roughness(Ra)
(mm/min) (gm/min)
1 40 50 1 1.17 1.921 0.0145
2 40 100 2 1.205 1.826 0.0135
3 40 150 3 1.235 1.368 0.013
4 40 200 4 1.3 1.85 0.0135
5 40 250 5 1.28 4.69 0.0135
6 50 50 2 1.15 2.9 0.015
7 50 100 3 1.11 3.7 0.0145
8 50 150 4 1.145 4.5 0.0155
9 50 200 5 1.205 4.9 0.0145
10 50 250 1 1.115 4.53 0.013
11 60 50 3 0.975 3.52 0.017
12 60 100 4 1.07 4.9 0.0155
13 60 150 5 1.135 6.19 0.014
14 60 200 1 1.105 4.76 0.0135
15 60 250 2 1.125 4.84 0.013
16 70 50 4 1.1 5.71 0.0135
17 70 100 5 1.125 6.63 0.017
18 70 150 1 1.065 7.02 0.015
19 70 200 2 1.175 6.75 0.016
20 70 250 3 1.175 6.574 0.0135
21 80 50 5 1.06 5.53 0.0145
22 80 100 1 1.045 5.69 0.015
23 80 150 2 1.115 7.57 0.0135
24 80 200 3 1.135 7.037 0.013
25 80 250 4 1.16 8.087 0.015

TABLE.2. Experimental results of Kerf Width, MRR and Surface Roughness and their S/N ratio’s

ABRASIVE
TRANSVERSE STAND OFF Surface
FLOW Kerf S/N MRR S/N Ratio
SPEED DISTANCE S/N Ratio roughness
RATE Width Ratio
(mm/min) (mm) (Ra)
(gm/min)
40 50 1 1.17 1.17691 0.0145 37.1206 1.921 4.5292

40 100 2 1.205 1.76186 0.0135 37.0168 1.826 5.34183

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

256
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

40 150 3 1.235 1.74189 0.013 37.5629 1.368 5.37703

40 200 4 1.3 2.30265 0.0135 37.3603 1.85 6.83383

40 250 5 1.28 2.25655 0.0135 37.6132 4.69 10.3073

50 50 2 1.15 0.920738 0.015 36.5855 2.9 9.76564

50 100 3 1.11 0.849753 0.0145 36.4888 3.7 10.1800

50 150 4 1.145 1.29409 0.0155 36.7462 4.5 12.4554

50 200 5 1.205 1.67370 0.0145 36.7642 4.9 14.2456

50 250 1 1.115 1.12348 0.013 37.3533 4.53 13.9554

60 50 3 0.975 0.183494 0.017 36.5723 3.52 10.4044

60 100 4 1.07 0.576817 0.0155 36.1869 4.9 13.0590

60 150 5 1.135 0.840009 0.014 36.6650 6.19 15.6677

60 200 1 1.105 0.715494 0.0135 37.0192 4.76 13.6942

60 250 2 1.125 1.04217 0.013 37.3330 4.84 14.9924

70 50 4 1.1 0.779600 0.0135 36.0622 5.71 14.5631

70 100 5 1.125 0.991775 0.017 35.8974 6.63 17.5511

70 150 1 1.065 0.750846 0.015 36.7117 7.02 16.3962

70 200 2 1.175 1.50323 0.016 36.7906 6.75 16.0110

70 250 3 1.175 1.17397 0.0135 37.1116 6.574 16.9109

80 50 5 1.06 0.630993 0.0145 36.4673 5.53 16.5743

80 100 1 1.045 0.339047 0.015 36.6387 5.69 15.7986

80 150 2 1.115 0.975012 0.0135 37.1777 7.57 16.2320

80 200 3 1.135 1.07146 0.013 37.2638 7.037 15.4486

80 250 4 1.16 1.20651 0.015 37.2960 8.087 18.5887

TABLE.3. ANOVA FOR GREY RELATIONAL GRADE

%
Source DF Seq. SS Seq. MS F-Value
Contribution

A 4 0.08289 0.020723 5.21 48.39

B 4 0.02907 0.007268 1.83 16.97

C 4 0.01161 0.002902 0.73 6.778

Error 12 0.04771 0.003976 27.85

Total 24 0.17128

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

257
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

TABLE.4.RESPONSE TABLE FOR GREY RELATIONAL GRADE (S/N RATIO)

Level Transverse Speed Abrasive Flow Rate Stand Off Distance

(A) (B) (C)
1 5.760 5.282 4.407
2 5.700 5.223 4.874
3 4.269 4.482 4.298
4 4.333 4.726 5.119
5 3.559 3.907 4.923
Delta 2.202 1.375 0.821
Rank 1 2 3

TABLE.5.RESPONSE TABLE FOR GREY RELATIONAL GRADE (MEANS)

Transverse Speed Abrasive Flow Rate Stand Off Distance

Level (A) (B) (C)
1 0.5167 0.5500 0.6080
2 0.5240 0.5493 0.5799
3 0.6144 0.6030 0.6148
4 0.6092 0.5896 0.5600
5 0.6672 0.6396 0.5688
Delta 0.1505 0.0903 0.0548
Rank 1 2 3

GRAPHS :

S/N Ratio plot for Grey relational grade

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

258
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

Main effect plot for Grey relational grade

PREDICTION OF RESPONSE VALUES FOR OPTIMUM LEVELS AS PER GREY-TAGUCHI TECHNIQUE:
From means of each level of process parameters we will construct a response table as following :

TABLE.6. RESPONSE TABLE FOR MEANS OF GREY-RELATIONAL GRADE

Stand Off
Level Transverse Speed (A) Abrasive Flow Rate (B)
Distance (C)
1 0.5167 0.5500 0.6080
2 0.5240 0.5493 0.5799
3 0.6144 0.6030 0.6148
4 0.6092 0.5896 0.5600*
5 0.6672* 0.6396* 0.5688
Delta 0.1505 0.0903 0.0548
Rank 1 2 3

From the response table the optimal condition for maximizing Metal Removal Rate, minimum Kerf Width
and Surface roughness simultaneously in Abrasive Water Jet Machining (AWJM) process, is found to be A5
B5 C3 i.e. Transverse speed is 80 mm/min, Abrasive Flow Rate is 250 gm/min and Stand Off Distance is 3
mm. For this optimal setting A5 B5 C4 conducted experimentation for validating results.

TABLE.7. OPTIMUM PARAMETER CONTROL LEVEL

Optimal Actual Experimental
Process response % of Error
setting Value Value
Metal Removal Rate 8.087 7.89 2.4
Kerf width A5 B5 C3 1.16 1.16 0
Surface Roughness 0.015 0.0155 -3.33
From the confirmation experiments, the error percentage of process responses from the predicted responses
is less than 5% is acceptable

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

259
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

VI. CONCLUSION Novovic, Amr Elfizy, Dragos A. Axinte, Stefan

Tnissen," Abrasive machining of advanced
In this present analysis of various parameters and on aerospace alloys and composites",CIRP Annals -
the basis of experimental results, analysis of variance Manufacturing Technology, Volume 64,Issue 2,
(ANOVA), and SN Ratio the following conclusions May 2015.
can be drawn for effective machining of INCONEL- [4]. Derzija Begic-Hajdarevic, Ahmet Cekic,
825 by AWJM process as follows: Muhamed Mehmedovic, Almina
Djelmic"Experimental Study on Surface
 Traverse Speed (TS) is the most significant factor Roughness in Abrasive Water JetCutting" 25th
on MRR during AWJM. Meanwhile Abrasive DAAAM International Symposium on
Flow Rate and Standoff distance is sub significant Intelligent Manufacturing and Automation,
in influencing. ISSN: 1877-7058, 2015.
 In case of surface Roughness Abrasive Flow Rate [5]. B Satyanarayana, G. Srikar," Optimization of
is most significant control factor. abrasive water jet machining process parameters
 In case of Metal Remove Rate (MRR) & Surface using Taguchi Grey RelationalAnalysis(TGRA)",
Roughness Transverse speed & Abrasive Flow Proceedings of 13th IRF International
Rate are most significant control factors. Conference, Pune , India, ISBN: 978-93-84209-
37-7, Issue 20,July 2014.
[6]. Vijay Kumar Pal, S.K.Choudhury“ APPLICATION
The optimal condition for maximizing Metal Removal OF ABRASIVE WATER JET MACHINING
Rate, minimum Kerf Width and Surface roughness INFABRICATING MICRO TOOLS FOR EDM FOR
simultaneously in Abrasive Water Jet Machining PRODUCING ARRAY OF SQUARE HOLES” All
(AWJM) process, is found to be A5 B5 C3 i.e. India Manufacturing Technology, Design and
Transverse speed is 80 mm/min, Research Conference (AIMTDR), December 12th–
Abrasive Flow Rate is 250 gm/min and 14th, 2014.
Stand Off Distance is 3 mm [7]. Sreekesh K and Dr. Govindan P“A REVIEW ON
ABRASIVE WATER JET CUTTING” International
VII. REFERENCES Journal of Recent advances in Mechanical
Engineering (IJMECH), Vol.3, No.3, August 2014.

[1]. D Patel, P. Tandon "CIRP Journal of [8]. S. R. Patel, Dr. A. A. Shaikh ,”Control and
measurement of abrasive flow rate in an Abrasive
Manufacturing Science and Technology", ISSN:
Waterjet Machine”,International journal of
1755-5817, September 10 (2015).
innovative Research in Science, Engineering and
[2]. N Tamannaee, J.K. Spelt, M. Papini," Abrasive
Technology, ISSN: 2319-8753 ,Volume 2,Issue
slurry jet micro-machining of edges, planar 12,December 2013.
areas and transitional slopes in a talc-filled co- [9]. Cristian Birtu, Valeriu Avramescu,” Abrasive water
polymer", Precision Engineering ,Department of jet cutting- Technique, Equipment,Performances”,
Mechanical and Industrial Engineering, Nonconventional Technologies Review,Romania,
University of Toronto, Department of Issue March ,2012.
Mechanical and Industrial Engineering, [10]. M. Chithirai Pon Selvan and N. Mohana Sundara
Ryerson University, Toronto, Canada , Issue 24, Raju“ASSESSMENT OF PROCESS PARAMETERS
June 2015. INABRASIVE WATERJET CUTTING
OFSTAINLESS STEEL” International Journal of
[3]. Fritz Klocke, Sein Leung Soo , Bernhard
Advances in Engineering & Technology (IJAET),
Karpuschewski, John A. Webster, Donka
ISSN: 2231-1963, July 2011.

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

260
 G. K. Kiran Kumar et al. Int. J. S. Res. Sci. Engg. Technol. September-October-2018; 4(10) : 248-261

[11]. Veselko Mutavgjic,Zoran Jurkovic, Marina

Franulovic, Milenko Sekulic,“Experimental
investigation of surface roughness obtained by
Abrasive Water jet machining”, 15th International
Research/Expert Conference ,“Trends in the
Development of Machinery and Associated
Technology”, Prague, Czech Republic , Issue
12,September 2011.
[12]. S. R. Patel, Dr. A. A. Shaikh ,"Control and
measurement of abrasive flow rate in an
Abrasive Waterjet Machine",International
journal of innovative Research in Science,
Engineering and Technology, ISSN: 2319-8753
,Volume 2,Issue 12,December 2013.
[13]. D. Patel, P. Tandon “CIRP Journal of
Manufacturing Science and Technology”
[14]. Fang-Jung Shiou, Assefa Asmare,”Parameters
optimization on surface roughness
improvement of Zerodur optical glass using an
innovative rotary abrasive fluid multi-jet
polishing process”, Precision
Engineering,Department of Mechanical
Engineering, National Taiwan University of
Science and Technology, Taiwan,Issue 17, April
2015

International Journal of Scientific Research in Science, Engineering and Technology ( www.ijsrset.com)

261

View publication stats