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

FACULTY OF ENGINEERING TECHNOLOGY

2015

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: _______________________

** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi

berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT

atau TERHAD.

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

Date :

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:

…………………

(Project Supervisor)

iv

ABSTRAK

Dalam proses pemotongan mesin, ketepatan pemotongan, masa pemotongan dan

kecacatan sifar adalah faktor yang sangat penting kerana produk yang berkualiti tinggi

mendapat permintaan tinggi di dalam industri. Terdapat beberapa faktor yang

menyebabkan masalah berlaku kerosakkan antaranya adalah getaran yang berlaku semasa

permulaan pemotongan dan pergerakan muncung semasa memotong. Masalah lain adalah

disebabkan oleh keupayaan mesin. Jubin adalah bahan rapuh dan mudah pecah

terutamanya pada kawasan pemotongan yang rumit. Terdapat tiga objektif yang ingin

dicapai dalam kertas kerja ini. Pertama adalah untuk menentukan Kadar Pembuangan

Bahan jenis jubin seramik menggunakan ‘Abrasive water jet’ (AWJ) dan kedua untuk

mengkaji potensi berlaku kecacatan pada reka bentuk sudut yang berbeza dan yang

terakhir adalah untuk mencari parameter pemotongan yang sesuai untuk memotong bahan

jubin seramik. Oleh itu terdapat tiga ujian yang akan dijalankan itu adalah ujian kadar

pembuangan bahan, ujian reka bentuk pada berlainan sudut dan kualiti permukaan

pemotongan. Selepas ujian dijalankan kertas kerja ini boleh menyimpulkan bahawa

keseluruhan objektif telah dicapai. Objektif pertama dicapai selepas mendapatkan

ketebalan tekanan yang sesuai, iaitu tekanan ketebalan 6mm (mesin). Objektif kedua

tercapai apabila dapat menentukan parameter yang boleh memotong jubin tepat di

samping mempunyai kos yang rendah. Objektif ketiga dapat dicapai selepas mendapatkan

ketebalan tekanan yang sesuai dan mendapat permukaan pemotongan yang baik. Selepas

melakukan pemerhatian tiga ujian ini, salah satu parameter yang terbaik telah dipilih iaitu

ketebalan tekanan 6mm (mesin).

v

ABSTRACT

In a machine cutting process, accuracy cutting, time cutting and zero defect is very

important factor because the demand is high to have a high quality product. There are

several factors that cause these problem most of the root cause is vibration during start

cutting done and the movement of the nozzle during cutting. The other problems are due

to design limitations. Tile is brittle material and easily to break especially in the intricate

cuts area. There are three objective needs to be achieve in this paper. First is to determine

the Material Removal Rate (MRR) of ceramic tile using AWJ and second to study the

potential defects at different angle design and the last is to recommended the suitable AWJ

cutting parameters to cut ceramic tile materials. Therefore there are three testing to be

carried out it is material removal rate experiment, design angle experiment and surface

quality experiment. After get the result it can be conclude that whole objective have been

achieved. The first objective was achieved after get the suitable pressure thickness, it is a

6mm pressure thickness (machine). The second objective are achieved when able to

determine which parameters can cut tile accurately in addition have a low cost. The third

objective get achieved after get the suitable pressure thickness versus surface roughness.

After doing the observation of three result, one of the best parameter was chosen that is

pressure thickness of 6mm in machine.

vi

DEDICATION

To my beloved parents and siblings.

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

.

Thank you very much.

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

1.3 Objective 3

1.4 Scope of Project 3

CHAPTER 2: LITERATURE REVIEW 4

2.1 Type of Machine 4

2.1.1: Conventional machine 5

2.1.2: Non-conventional machine 5

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

3.4.1: Material removal rate experiment 27

3.4.1.1: Procedure of material removal rate experiment 28

3.4.1.2: Data collection table for material removal rate experiment 28

3.4.2: Design angle experiment 29

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

A Gantt chart PSM 1

B Gantt chart PSM 2

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

1.3 Objective 3

1.4 Scope of Project 3

CHAPTER 2: LITERATURE REVIEW 4

2.1 Type of Machine 4

2.1.1: Conventional machine 5

2.1.2: Non-conventional machine 5

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

3.4.1: Material removal rate experiment 27

3.4.1.1: Procedure of material removal rate experiment 28

3.4.1.2: Data collection table for material removal rate experiment 28

3.4.2: Design angle experiment 29

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

A Gantt chart PSM 1

B Gantt chart PSM 2

xi

LIST OF TABLE

3.1: Specifications of Flow Waterjet MACH2 25

3.2: Name of ceramic tile 26

3.3: Specification of ceramic tile 26

3.4: Example table for material removal rate experiment 28

3.5: Example table result of design angle experiment 30

3.6: Example table for data of abrasive cost 31

3.7: Example table data collection for surface quality experiment 32

3.8: Example of parameter selection table 33

4.1: Result for material removal rate experiment 34

4.2: Result for design angle experiment.design angle experiment. 37

4.3: Costing result for design angle experiment. 38

4.4: Result for surface quality experiment 39

4.5: Parameter selection 42

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

3.6 Profile projector machine 31

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

4.6 Box plot of surface roughness vs pressure 43

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

ANOVA - Analysis of Variance

1

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).

Abrasive water jet was selected because it does not have contact with tools, no heat zone

and low machining force when cutting is apply. While temperature at the impact zone can

be very high, total temperature is low. The presence of a high speed waterjet acts very

effective convective coolant as well. Hence, AWJ is most suitable for machining heat-

sensitive and hard to machine materials. The AWJM is able to cut any material and can be

used without using a fixtures modification or special fixtures or tooling. In AWJM the same

cutting tool can be used for drilling, milling, turning, and contouring of virtually any

geometry; possibility, replacing an entire work shop of machine tools. So it is very suitable

for use in this experiment, because in this experiment, there are many types of cutting used

for the purpose of obtaining state MRR rate and there are several types of tiles are used to

cut and to make analysis. AWJM is simply composed of water and some naturally

occurring minerals. It does not require synthetic oils or other chemicals for lubrication and

cooling. All components of an AWJ are environmentally friendly and recyclable. (Mark et

al. 2011).

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

There are several factors that cause these defects to occur, which are caused by

vibration from beginning of the cutting and the movement of the nozzle during cutting

(Orbanic, 2008). Tile is a brittle material and easily to brake during cutting. Abrasive water

jet cutting machine usually causes cracks in the intricate cuts area. Besides that, a lot of

material waste after the cutting is done. Therefore the main objective of this study are as

following.

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

This study focuses on different materials of ceramic tiles namely mosaic tile, stone tile,

ceramic tile, vitrified tile. Used the abrasive water jet model Flow Water jet MACH2.

Abrasives used in this study of size 13/40 with 80 mesh. Data is analyze material using

Excel and T-Test (Minitab). Digital camera is used to capture the defect images of tiles.

The MRR of each sample is obtained by weighing the material before and after experiment

is use the digital scales.

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

Machining processes produce finish product with a high degree of accuracy and surface

quality. The need for higher machining productivity, product accuracy, and surface quality

will led to the combination of two or more machining actions. (Helmi et al. 2008)

5

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.

Nowadays, non-conventional machining process are generally classified into different

type of energy utilized in material removal such as mechanical processes. In mechanical

process, material removal is depends on mechanical abrasion or shearing. It will

integrating two or more non-conventional process to improve the performance of the

removal rate in the hybrid process (HP). The example of the mechanical process is

electrochemical grinding (ECG), electrochemical honing (ECH), electrochemical

ultrasonic machining (ECUSM) and abrasive water jet machining (AWJM) (Hassan,

2005).

6

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).

2.2.1 Abrasive water jet machining equipment

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