Augmenting the design of a nozzle used in abrasive jet machining process with computational fluid dynamics

The nozzle is an important part that affects the performance of the abrasive jet machining. It is a micromachining process, where the target material is being eroded by the effect of a high-speed continuous flow of abrasive particles, which are move out from a nozzle. A nozzle is required to carry out the particles to remove the material with the help of a large velocity of the microjet. The common nozzle shape presently used in this process is a rectangle and circular shape, which gives a low flow rate and further demands to reduce the material removal rate (MRR). In this work, three different geometrical types of nozzles: (i) convergent nozzle (25 mm) length, (ii) convergent nozzle (50 mm) length, (iii) modified convergent nozzle has been designed. The simulations of the flow have been analyzed using computational fluid dynamics. The velocity and pressure of the particles inside the nozzle were compared. The results show the improvements in the modified convergent nozzle are about 42.84 m/s of velocity and the pressure inside the nozzle tip is about 994424.5 Pa. Due to the swirl flow in a modified convergent nozzle, the high material removal rate is achieved. (C) 2020 Elsevier Ltd. All rights reserved.