OPTIMIZATION OF ABRASIVE JET MACHINING PROCESS PARAMETERS IN WOVEN SILK REINFORCED COMPOSITE

OPTIMIZATION OF ABRASIVE JET MACHINING PROCESS PARAMETERS IN WOVEN SILK REINFORCED COMPOSITE

1. Under the guidance of DINESH S V Dr. S.MOHANASUNDARAM URK18ME076 Assistant Professor B.Tech in Mechanical Engineering OPTIMIZATION OF ABRASIVE JET MACHINING PROCESS PARAMETERS IN WOVEN SILK REINFORCED COMPOSITE

2. Objectives To objective of the project is fabricate the polymer composite using multiple layer of natural fiber which is silk in the form of a fabric. To conduct testing for identification of the mechanical properties like tensile strength, flexural strength. Using abrasive water jet machine, the composite was machined with various process parameters to obtain optimized surface roughness and material removal rate

3. Natural Fiber Reinforced Polymer Composites Natural fiber composites are produced by combining various natural fiber preforms and matrix resins derived from natural polymers or synthetic polymers . Th e application is due to its totally biodegradable, relatively good mechanical properties, available and renewable sources as compared to synthetic fibers The applications of NFPCs are found in building and construction, aerospace, sports, and more, such as partition boards, ceilings, boats, office products, and machinery

4. S. NO Title Author / journal/year Inference 1 . Silk as a Natural Reinforcement: Processing and Properties of Silk/Epoxy Composite Laminates Youssef K. Hamidi , M. Akif Yalcinkaya , Gorkem E. Guloglu , Maya Pishvar , Mehrad Amirkhosravi and M. Cengiz Altan Specific mechanical properties of silk/epoxy laminates were found to be anisotropic and comparable to those of glass/epoxy. Silk composites even exhibited a 23% improvement of specific flexural strength along the principal weave direction over the glass/epoxy laminate. 2. Waste Silk Fiber Reinforced Polymer Matrix Composites: A Review S. M. Darshan , B. Suresha ,, G. S. Divya The waste silk fibers may be a potential as reinforcement for effectively improving the static and dynamic mechanical properties of a biodegradable polymer matrix resin 3. Experimental study on preparation and mechanical characteristics of jute/silk/coco-peat reinforced with epoxy polymers K. Raghavendra Pai , K.S. Lokesh , D. Shrinivasa Mayya , J.R. Naveen Kumar, Ajit M. Hebbale . In this work, we have selected jute and silk as reinforce materials (60%), coco peat as filler material (3%) and Epoxy resin ( Lapox , L-12 with hardener K-6) as a matrix material (37%). 4. Abrasive water jet machining of fiber -reinforced composite materials. Vigneshwaran Shanmugam , M. Uthayakumar , V. Arumuga Prabu . However, several nonconventional methods have been adopted for machining composites, in which abrasive water jet machining (AWJM) was proven to be more effective and a preferable technique in machining of fiber -reinforced composite material 5. Performance Evaluation of Abrasive Water Jet Machining on Banana Fiber Reinforced Polyester Composite V. Arumuga Prabu , S. Thirumalai Kumaran , M. Experiments are conducted to assess the influence of each input parameters on the output responses namely surface roughness (Ra) and kerf angle. The study is performed by varying the water pressure, traverse speed (TS), and standoff distance (SD). Literature Survey

5. Methodology

6. Materials used Woven silk fiber Epoxy Resin LY556 Hardener HY951

7. Fabrication Hand layup Method

8. Abrasive Water Jet Cutting Specifications Nozzle material Tungsten Carbide Nozzle diameter 0.9 mm Accuracy ± 0.05 mm

9. Process Parameters

10. Machined Specimens

11. Experimental Testing The maximum tensile strength obtained is 36.4 N/mm 2 . The maximum bending stress obtained is 1.9 N/mm 2 . A roughness tester is used to quickly and accurately determine the surface texture or surface roughness of a material.

12. Effects of process parameters on Surface Roughness (Bar) (g/min ) Process parameters and Values Water pressure 80 bar 3.29µm Flow rate 300g/min 2.58 µm Traverse speed 600mm/min 3.92µm

13. Effects of process parameters on Material Removal Rate (Bar) ( g/min) Process parameters and Values Water pressure 70 bar 19.20g/mm 3 Flow rate 300g/min 22.84g/mm 3 Traverse speed 200mm/min 23.38g/mm 3

14. Uncertainty Error Analysis of Surface Roughness The maximum uncertainty of ± 6% is obtained which is well within the permitted ± 3σ limits.

15. Uncertainty Error Analysis of Material Removal Rate The maximum uncertainty of ±5 % is obtained which is well within the permitted ± 3σ limits.

16. Grey Relational Analysis

17. Optimized Process Parameters

18. Conclusion The tensile strength and bending stress obtained are 36.4 N/mm 2 and 1.9 N/mm 2 . The better surface roughness’s are achieved for the water pressure of 80 bar, abrasive flow rate of 300 g/min and traverse speed of 600 mm/min are 3.29 µm , 2.58 µm and 3.92 µm respectively. The better results of effect of process parameter on material removal rate are achieved with 70 bar water pressure as 19.20 g/mm 3 , with abrasive flow rate 300 g/min as 22.84 g/mm 3 and with 200 mm/min traverse speed as 23.88 g/mm 3 . The uncertainty analysis of Surface Roughness and Material Removal Rate is ± 5% and is obtained which is well within the permitted ± 3σ limits respectively. The optimized process parameters combination is achieved with water jet pressure 70 bar, abrasive flow rate 250 g/min, traverse speed 400 mm/min as Surface Roughness of 3.288 µm and Material Removal Rate of 16 g/mm 2 .

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