Effect of rotation direction, traverse speed, and abrasive type during the hydroabrasive disintegration of a rotating Ti6Al4V workpiece

Abstract

In this study, a new methodology is considered for determining the rotational senses (clockwise or anti-clockwise) of a workpiece during the hydroabrasive disintegration of rotating samples. The rotational directions are taken with respect to the position of the abrasive jet, that is, keeping it on the right side of the rotating workpiece when viewed from the free end in the cartesian coordinate system. Measurements were carried out for diameter deviation, material removal rate and surface roughness as a response to machining parameters such as traverse speed, workpiece rotation direction and abrasive grain. Final diameter of the workpiece (10.28-14.12 mm), material removal rate (1154-3936 mm(3)/min) and surface roughness (6.65-25.43 mu m) values increase with increasing value of traverse speed (5-25 mm/min) using anti-clockwise rotation with Australian garnet abrasive grains. ANOVA analysis of the responses shows that traverse speed (p = 0.000) is a statistically significant parameter for predicting all the machining responses. Abrasive type and rotational direction were statistically significant for determining diameter deviation (p = 0.017, 0.006) and material removal rate (p = 0.000, 0.000) but insignificant for surface roughness (p = 0.373, 0.367). Scanning electron microscopy provided information on the surface morphology, depicting the characteristics of the disintegrated surface. Disintegrated features, like peak and valley formations, craters, holes, cutting traces and embedded abrasive particles on the surface were observed.