MAXIMIZATION OF WEAR RATES THROUGH EFFECTIVE CONFIGURATION OF STANDOFF DISTANCE AND HYDRAULIC PARAMETERS IN ULTRASONIC PULSATING WATERJET

Abstract

A pulsating waterjet is a technological modification of a conventional waterjet that utilizes ultrasonic vibrations to generate a modulated jet, resulting in repetitive fatigue loading of the material. The erosion efficiency of the ultrasonic pulsating waterjet is majorly determined by the hydraulic factors and its interaction with standoff distance. However, the dependency of the wear rates on different hydraulic factors and formulation of an implicit prediction model for determining effective standoff distance is still not present to date. Therefore, in this study, the combined dependency of the supply pressure (20-40 MPa), nozzle diameter (0.3-1.0 mm), and standoff distance (1-121 mm) on wear rates of AW-6060 aluminum alloy are studied. Statistical analysis is used to determine the statistically significant factors and formulate regression equations to determine output responses within the experimental domain. The surface topography and sub-surface microhardness of the eroded grooves were studied. The results show that both the disintegration depth and the material removal increase with an increase in the nozzle diameter and supply pressure. However, the dependency of the output responses on nozzle diameter is statistically more evident than supply pressure and two-way interactions. Cross-sectional images of the grooves showed typical hydrodynamic erosion characteristics in erosion cavities, subsurface voids, and material upheaving. The results of microhardness analysis showed an approximately 15-20% increase in hardness values compared to the untreated samples.