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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

EFFECTS OF ABRASIVE ON CERAMIC TILE CUTTING

PROCESS USING ABRASIVE WATER JET MACHINE (AWJ)

This report submitted in accordance with requirement of the UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM) for the Bachelor Degree of Manufacturing

Engineering Technology (Process and Technology) (Hons.)

by

MUHAMMAD AISAMUDDIN BIN IDRIS B071110352

890923045205

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UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

TAJUK: EFFECTS OF ABRASIVE ON CERAMIC TILE CUTTING PROCESS USING ABRASIVE WATER JET MACHINE (AWJ)

SESI PENGAJIAN: 2014/15 Semester 1

Saya MUHAMMAD AISAMUDDIN BIN IDRIS

mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk

tujuan pengajian sahaja dengan izin penulis.

3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. **Sila tandakan ( )

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)

(TANDATANGAN PENULIS) Alamat Tetap:

J 8461 KM 14 Kampung Berangan Enam Umbai 77300 Merlimau,

Melaka Bandaraya Bersejarah.

Tarikh: ________________________

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi:

Tarikh: _______________________

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ii

DECLARATION

I hereby, declared this report entitled “Effects of Abrasive Consumption on Tile Cutting Process of Abrasive Water Jet Machine (AWJ)” is the result of my own research except

as cited in references.

Signature : ………...

Author’s Name : MUHAMMAD AISAMUDDIN BIN IDRIS

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iii

APPROVAL

This report is submitted to the Faculty of Engineering Technology UTeM as a partial fulfillment of requirements for the degree of Manufacturing Engineering Technology (Process and Technology) (Hons.). The member of the supervisory committee is as follow:

………

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iv

ABSTRAK

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v

ABSTRACT

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vi

DEDICATION

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vii

ACKOWLEDGEMENT

In the name of Allah, the Most Gracious and the Most Merciful Alhamdulillah, all praises to Allah for the strengths and His blessing in completing this thesis. Special appreciation goes to my supervisor, Engr. Hanizam bin Hashim, for his supervision and constant support. His invaluable help of constructive comments and suggestions throughout the experimental and thesis works have contributed to the success of this research. Not forgotten, my appreciation to my co-supervisor, Mr Mohd Kamal bin Musa for his support and knowledge regarding this topic.

I would like to express my appreciation to the Dean, Faculty of Engineering Technology, Assoc. Prof. Mohd Rahimi Bin Yusoff for his support and help towards my postgraduate affairs. My acknowledgement also goes to all the technicians and office staffs of Faculty of Engineering Technology for their co-operations.

Sincere thanks to all my friends for their kindness and moral support during my study. Thanks for the friendship and memories. Last but not least, my deepest gratitude goes to my beloved parents; Mr Idris bin Menhad , Mrs. Esah binti M.Haniff and all my family for their endless love, prayers and encouragement. To those who indirectly contributed in this research, your kindness means a lot to me

.

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viii

TABLE OF CONTENT

Dedication ii

Approval iii

Abstrak vi

Abstract v

Dedication vi

Acknowledgment vii

Table of Content viii

List of Tables xi

List of Figures xii

List Abbreviations, Symbols and Nomenclatures xiv

CHAPTER 1: INTRODUCTION 1

1.1 Background 1

1.2 Problem statement 2

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ix

2.2: Abrasive water jet machine 6 2.2.1: Abrasive water jet machining equipment 6 2.2.2: Mixing abrasive with water 7

2.2.3: Advantages 8

2.2.4: Limitations 8

2.3: Impact Abrasive Machine 9 2.3.1: Material removal by impact 10

2.3.1.1: Ductile erosion 11 2.3.1.2: Brittle erosion 12 2.3.2: Material removal by abrasive jet 13 2.4: Sample to be study 16 2.4.1: Ceramic tile 16

2.5: Tile design 17

2.6: Type of defect 19

2.5.1: Tiling defect 20 2.7: Profile projector machine 21

CHAPTER 3: METHODOLOGY 23 3.1: Project planning 24 3.2: Machine specification 25 3.2.1: Specifications 25 3.3: Characteristic of tile 26 3.3.1: Ceramic tile 26

3.4: Experimentation 27

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x

3.4.2.1: Procedure of design angle experiment 30 3.4.2.2: Data collection table for Design angle experiment 30 3.4.3: Surface quality experiment 31 3.4.3.1: Procedure of surface quality experiment 31 3.4.3.2: Data collection for surface quality experiment 32 3.5: Parameter selection 33 3.5.1: Table data collection 33

CHAPTER 4: RESULT AND DISCUSSION 34 4.1: Material removal rate experiment 34 4.1.1: Observation test result of design angle experiment 35 4.2: Design angle experiment 36 4.2.1: Observation test result of design angle experiment 39 4.3: Surface quality experiment 39 4.3.1: Observation test result of surface quality experiment 41 4.4 Parameter selection 42

CHAPTER 5: CONCLUSION AND RECOMMENDATION

5.1: Conclusion 43

5.2: Recommendation 44

REFERENCES 45-46

APPENDICES

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viii

TABLE OF CONTENT

Dedication ii

Approval iii

Abstrak vi

Abstract v

Dedication vi

Acknowledgment vii

Table of Content viii

List of Tables xi

List of Figures xii

List Abbreviations, Symbols and Nomenclatures xiv

CHAPTER 1: INTRODUCTION 1

1.1 Background 1

1.2 Problem statement 2

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ix

2.2: Abrasive water jet machine 6 2.2.1: Abrasive water jet machining equipment 6 2.2.2: Mixing abrasive with water 7

2.2.3: Advantages 8

2.2.4: Limitations 8

2.3: Impact Abrasive Machine 9 2.3.1: Material removal by impact 10

2.3.1.1: Ductile erosion 11 2.3.1.2: Brittle erosion 12 2.3.2: Material removal by abrasive jet 13 2.4: Sample to be study 16 2.4.1: Ceramic tile 16

2.5: Tile design 17

2.6: Type of defect 19

2.5.1: Tiling defect 20 2.7: Profile projector machine 21

CHAPTER 3: METHODOLOGY 23 3.1: Project planning 24 3.2: Machine specification 25 3.2.1: Specifications 25 3.3: Characteristic of tile 26 3.3.1: Ceramic tile 26

3.4: Experimentation 27

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x

3.4.2.1: Procedure of design angle experiment 30 3.4.2.2: Data collection table for Design angle experiment 30 3.4.3: Surface quality experiment 31 3.4.3.1: Procedure of surface quality experiment 31 3.4.3.2: Data collection for surface quality experiment 32 3.5: Parameter selection 33 3.5.1: Table data collection 33

CHAPTER 4: RESULT AND DISCUSSION 34 4.1: Material removal rate experiment 34 4.1.1: Observation test result of design angle experiment 35 4.2: Design angle experiment 36 4.2.1: Observation test result of design angle experiment 39 4.3: Surface quality experiment 39 4.3.1: Observation test result of surface quality experiment 41 4.4 Parameter selection 42

CHAPTER 5: CONCLUSION AND RECOMMENDATION

5.1: Conclusion 43

5.2: Recommendation 44

REFERENCES 45-46

APPENDICES

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xi

LIST OF TABLE

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xii

LIST OF FIGURE

2.1 Schematic of an abrasive waterjet (AWJ) system 6

2.2 Ductile and brittle erosion modes 11

2.3 Material displacement and removal by successive particles impact 12

2.4 Brittle erosion by cracking and fragmentation 13

2.5 Step formatting during abrasive jet travers 14

2.6 Cross section of machined groove 15

2.7: Example tile design with dimension 17

2.8: Template of tile design 18

2.9: Example of tile decoration 18

2.10 Type of defect 19

2.11: Schematic of profile projector machine 22

3.1 Flow chart for the research methodology 24

3.2 Flow Waterjet MACH2 25

3.3 Ceramic tile 26

3.4 Cutting path for material removal rate experiment. 27

3.5 Cutting path of design angle experiment 29

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xiii

4.1 Graph material removal rate (MRR) vs pressure thickness 35

4.2 Actual distance for experiment. 36

4.3 Reference point for Table 37

4.4 Chart cost of abrasive 38

4.5 Reference point for surface quality experiment 41

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xiv

LIST OF ABBREVIATIONS, SYMBOLS AND

NOMENCLATURE

AWJM - Abrasive water jet machine

WJM - Water jet machine

MRR - Material removal rate

HP - Hybrid process

ECG - Electrochemical grinding

ECH - Electrochemical honing

ECUSM - Electrochemical ultrasonic machining

MPa - Mega Pascal

L - Litre

d𝑔 - Diameter

µm - Micron meter

mm - Millimeter

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CHAPTER 1

INTRODUCTION

1.1 Background

Nowadays, many process use advance machining such as chemical process, electrochemical process, thermal process and hybrid electrochemical process. The Abrasive Water Jet Machine (AWJM) is one of the advance machining process. AWJM is suitable to cut harder material such as glass, ceramics, concrete, and tough composites can be cut by adding abrasives to the water jet during abrasive water jet machining (Hassan, 2005).

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2

Abrasive water jet (AWJ) is a new technique for cutting difficult to machine materials and make cutting without reducing the properties of material (Pang & Wang, 2009). The AWJ typically used in industry to cut ceramics, or hard material (El-Hofy, 2005). AWJ uses an abrasive to do the cutting path on the work piece using compress water and released through a nozzle. Because of the high velocity, the cutting could be done quickly. This machine cuts almost all types of materials (conductive and nonconductive). Where the traditional machine unable to perform effectively especially on brittle and ductile materials. Non conversional machining process have been introduced to do cutting and improve the productivity compared to traditional machine (Palleda, 2007).

In this study, many types of tile are selected for testing to obtain the material removal rate (MRR). This material was chosen because it easy to cutting, obtain MRR and flow rate. This study also aim to determine the cause of the cracks and other possible defects. So the easiest way to examine the damage and cracking is by using a digital camera pictures and make comparison analysis.

1.2 Problem statement

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3

1.3 Objective

1) To determine the Material Removal Rate (MRR) of ceramic tile using AWJ.

2) To study the potential defects at different angle design.

3) To recommended the suitable AWJ cutting parameters to cut ceramic tile materials.

1.4 Scope of project

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4

CHAPTER 2

LITERATURE REVIEW

From the early stage of the project, various literatures studies have been done. Research journal, reference book, printed or on line conference article were the main sources of information. This chapter review topics such as Abrasive water jet machine (AWJ), impact AWJ machine, and methods to perform correlations analysis.

2.1 Type of machine

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2.1.1 Conventional machine

During recent years, engineering materials have been greatly developed. The conventional machine such as lathe machine, milling machine and drilling machine also is impossible to machine hard material to certain shape. This is because the conventional method is not suitable to machine some of the material economically and it is harder than the materials that available for cutting tools. By using conventional machine, the cutting speed and MRR is not consistence. It is possible to find tools material that are hard to cut such as hardened steels, austenitic steels, carbides, ceramics and fiber-reinforced composite material. (Helmi et al. 2008)

2.1.2 Non-conventional machine.

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2.2 Abrasive water jet machine

Water jet machining (AWJM) is suitable for cutting plastics, rubber insulation, automotive carpeting and headlines, and most textiles. Other than that, AWJ machine suitable for cutting hard material such as glass, ceramics, concrete and tough composites. AWJM was first developed in 1974 to clean metal prior to surface treatment of the metal. Generally, AWJM cuts 10 times faster than conventional machining (Hassan, 2005).

[image:24.612.218.437.355.663.2]

2.2.1 Abrasive water jet machining equipment

Figure

Figure 2.1: Schematic of an abrasive waterjet (AWJ) system.

References

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