Saumil Patel

Publication Date


Document Type


First Advisor

Majumdar, Pradip, 1954-

Degree Name

M.S. (Master of Science)

Legacy Department

Department of Mechanical Engineering


Metal-cutting; Water jet cutting


Abrasive water jet (AWJ) cutting is one of the most developing technologies for metal cutting process. It is superior in processing very difficult to cut material which are highly sensitive to temperature variation compared to other machining processes. Although cutting capability in terms of surface roughness, depth of jet penetration and kerf quality are the major obstructions limiting its pertinence, more study is required to understand the cutting process and cutting mechanism, and to optimize cutting performance. This research is to conduct comparative study of effecting parameters such as abrasive mass flow rate, standoff distance of nozzle from workpiece, water pressure and nozzle traverse speed to achieve fine surface roughness (Ra), minimize kerf taper and to attain maximum depth of cut. Series of experiments are conducted on Aluminum 6061 sheet by changing effecting parameters on OMEX AWJ machine; resulted surface roughness (Ra) and kerf taper are measured using surface roughness tester and microscopes. Resulted data has been analyzed in Minitab 17 and Rstudio data analysis software. ANOVA (analysis of variance) outcome shows that nozzle travel speed and water pressure have major effect on surface roughness of cut metal. It also shows that abrasive flow rate and nozzle travel speed have significant effect on kerf taper angle variation; all other process parameters have negligible effect on surface quality. Interaction plots among variables are generated. Finite element analysis is carried out to get the physical understanding of the erosion process in the AWJ. Finite element analysis results show that generated equivalent stresses from force exerted by high-velocity abrasive water jet are exceeding the maximum yield stress of Aluminum-6061, and it can be deduced that material will start to deform/remove.


Advisors: Pradip Majumdar.||Committee members: Jenn-Terng Gau; Rao Kilaparti.||Includes bibliographical references.||Includes illustrations.


viii, 56 pages




Northern Illinois University

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