Experimental and simulation approach of surface generation on K-80 alumina ceramic by recently developed sustainable FB-HAJM using novel nozzle design

Abstract

K-80 alumina ceramic makes it challenging to machine them economically due to extreme hardness. Fluidized bed-hot abrasive jet machining (FB-HAJMing), in which a target profile is eroded by the impingement action of air-hot abrasive jet, which containing fine hot abrasive grains for machining of K-80 alumina ceramic materials without thermal damage. This study is intended to analyse kerf angle (KA), surface roughness (Rz) and material removal rate (MRR) using HAJMing process of K-80 alumina ceramic. Fifteen sets of experimental trials were conducted two times using tungsten carbide (WC) nozzle with and without internal thread. The identified three cutting parameters i.e., air pressure (P), abrasive temperature (T) and stand-off-distance (SOD), were considered for experimental design. Furthermore, the response surface methodology (RSM), statistical techniques (here, desirability function approach) followed by computational approach (here, genetic algorithm) are respectively employed for experimental investigation, predictive modelling and multi-objective optimization. Subsequently, confirmation tests evaluate the efficiency of the suggested two multi---objective optimization methods to rationalize the utility and awareness of the usefulness of hot abrasives in HAJMing. Moreover, computational fluid dynamics (CFD) modelling was utilized to develop a comprehensive relation between HAJMed profile geometry and erosive flow. Finally, the environmental ‘Pugh Matrix’ approach is proposed for the HAJMing process sustainability evaluation. The results indicated a desire to improve the cutting efficiency for material erosion by using hot abrasives in the HAJMing procedure. The most important parameter for surface roughness is abrasive temperature, while pressure is important for both KA and MRR. The use of hot abrasives in the FB-HAJM process has demonstrated a focus on improving the cutting performance for material removal. From an economic standpoint, the current study presents a technological criterion for feasible industrial applications of the FB-HAJM method, such as in aerospace, precision manufacturing, and biomedical field.