A new cutting depth model with rapid calibration in abrasive water jet machining of titanium alloy

Bui, Van Hung; Gilles, Patrick; Sultan, Tarek; Cohen, Guillaume; Rubio, Walter

doi:10.1007/s00170-017-0581-x

Cited by 28 publications

(36 citation statements)

References 16 publications

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“…[23][24][25][26][27] With respect to the processing mechanism, the abrasive flow in the abrasive water jet polishing and abrasive flow machining methods has a strong impact or high viscosity by exerting a strong jet force or squeeze pressure, in which the workpiece surface is strongly cut by the abrasive particles. [28][29][30] In this article, the abrasive flow in these processing methods is referred to as ''hard'' abrasive flow. Although the processing method of using ''hard'' abrasive flow has high processing efficiency, it is difficult to get the satisfactory surface roughness because it may leave clear and directional machining marks on the surface of the workpiece by the strong circulation and strong pressure reciprocation to drive abrasive flow.…”

Section: Introductionmentioning

confidence: 99%

An ultrasonic-assisted soft abrasive flow processing method for mold structured surfaces

Zhu

2019

Advances in Mechanical Engineering

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As a fluid-based precise processing method, soft abrasive flow processing has been widely used in advanced electromechanical systems, complex mold manufacturing, and other engineering fields. Because of the low volume fraction of abrasive particles and micro-force/cutting removal characteristics, there exists a potential improvement in terms of processing efficiency and uniformity. In view of the above problems, this article presents an ultrasonic-assisted soft abrasive flow processing method. Based on the realizable k–ε turbulence model and the mixture flow model, an ultrasonic coupling enhancement dynamic model for soft abrasive flow is set up, and the kinetic energy transport equation of realizable k–ε turbulence model can be revised. Using particle image velocimetry technology, an on-line observation experimental platform for ultrasonic-assisted soft abrasive flow is developed to conduct the real-time acquisition of abrasive flow state and particle distribution in a constrained flow passage. An ultrasonic-assisted soft abrasive flow processing experimental platform is established to complete the processing experiment. The experimental results show that the ultrasonic excitation vibration can effectively enhance the turbulence intensity and distribution uniformity of the abrasive flow, the average processing time can be shortened by more than 6 h, and a better surface quality can be obtained.

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Section: Introductionmentioning

confidence: 99%

An ultrasonic-assisted soft abrasive flow processing method for mold structured surfaces

Zhu

2019

Advances in Mechanical Engineering

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“…These prediction models have a good correlation with the experimental measurements (error < 10%) and can be easily calibrated thanks to few tests. Similar models have been developed for titanium AWJ machining [23,24] and the maximum depth of cut as well as the whole trench or pocket profiles have been properly predicted (error < 5% for [24]). It is important to mention that empirical or analytical models seem to be the most suitable prediction method for an industrial use due to its simple and fast calibration and usage.…”

mentioning

confidence: 88%

“…The choice of the variable parameters is the conclusion drawn from a review concerning milling with AWJ. It was shown that the water jet pressure, the traverse speed and the scan step are the most influent parameters on the pocket's geometry [7,15,24,26,27]. In this case, four levels of pressure were selected as this parameter was found to be the most influent on the depth of cut [7,24,27].…”

Section: Abrasive Water Jet Milling Machine and Parametersmentioning

confidence: 99%

“…However, this model has been adapted for the 3D woven composite. The second model is based on Gauss model mainly used for the prediction of an elementary pass previously used by [23,24,31] when machining isotropic material. Thanks to the measurement of the effective jet diameter, the last model has been adapted and improved for milling 3D woven composite.…”

Section: Mm)mentioning

confidence: 99%

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New model for the prediction of the machining depth during milling of 3D woven composite using abrasive waterjet process

Sourd

Zitoune

Crouzeix

et al. 2020

Composite Structures

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The goal is to study the influence of abrasive water jet (AWJ) machining parameters (jet pressure, traverse speed and scan step) on the cutting depth of 3D woven Carbon Fibres Reinforced Polymer (CFRP) composite. The original material linked to this non-conventional milling process has not been treated yet. The depths of cut were measured and characterized as a function of the machining parameters. Finally, two prediction models for the cutting depth are proposed and validated experimentally. An increase in cutting depth with the pressure and a decrease as the traverse speed and/or the scan step increase were observed. The first prediction model, based on the pocket depth measurements, has a mean error of 5%. However, the error increases (up to 23%) when the pocket becomes shallow (lesser than 1 mm). The second prediction model, based on the algebraic sum of elementary passes modelled with Gaussian bells, shows at first a mean error of 12%. A correction was performed depending on the erosion regime piloted by the depth of the elementary trench constitutive of the pocket. This enhancement, performed thanks to the primary jet diameters measurements with high speed camera, has improved the second model with a mean error of 5% (error < 16%).

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“…Because of the high feed speed acceleration and deceleration procedures of the manufacturing machine have to be considered for this operation [11]. To quickly design AWJ milling operations, van Bui et al [12] have suggested the use of the Gaussian curve and its superposition to describe the material removal of the operation. Although a lot of fundamental and application knowledge about AWJ milling operations has been achieved [13], the application of the technology for industrial purposes is limited.…”

Section: Introductionmentioning

confidence: 99%

Efficient abrasive water jet milling for near-net-shape fabrication of difficult-to-cut materials

Uhlmann

Männel

Braun

2020

Int J Adv Manuf Technol

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The utilization of materials with high strength to density ratio enables efficiency improvements and is therefore demanded for many applications, particularly in the aerospace and other mobility sectors. However, the machining of these typically difficult-to-cut materials poses a challenge for conventional manufacturing technologies due to the high tool wear. Abrasive water jet (AWJ) machining is a promising alternative manufacturing technology for machining difficult-to-cut materials, since the tool wear is low and material independent. However, AWJ machining is limited regarding the producible geometries when conducting cuts through a material. This limitation can be resolved with AWJ milling operations which on the other hand are time-consuming. To approach this challenge, an enhanced AWJ milling operation is presented and investigated in this paper with the aim to expand the producible geometries. This operation consists of two kerfs, inserted from different sides of the workpiece, which intersect at their kerf ground. Consequently, a piece of material is separated without the cut material being entirely chipped. Thus, the operation possesses a high aggregated material removal rate. The investigations presented in this paper show and evaluate the effects that occur during the milling of kerfs with variable depths on titanium aluminide TNM-B1. Furthermore, a method to compensate these effects is introduced and thus the producible geometries for effective AWJ milling could be enhanced.

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A new cutting depth model with rapid calibration in abrasive water jet machining of titanium alloy

Cited by 28 publications

References 16 publications

An ultrasonic-assisted soft abrasive flow processing method for mold structured surfaces

An ultrasonic-assisted soft abrasive flow processing method for mold structured surfaces

New model for the prediction of the machining depth during milling of 3D woven composite using abrasive waterjet process

Efficient abrasive water jet milling for near-net-shape fabrication of difficult-to-cut materials

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