Abrasive waterjet micro-machining of channels in metals: Model to predict high aspect-ratio channel profiles for submerged and unsubmerged machining

Haghbin, Naser; Spelt, J.K.; Papini, M.

doi:10.1016/j.jmatprotec.2015.03.026

Cited by 47 publications

(23 citation statements)

References 21 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Kong [15] found that the MRR increased with increase in pressure, accompanied by uniform material erosion and low surface waviness. Haghbin et al [16] comparatively investigated AWJ milling and high-pressure abrasive slurry jet milling and observed that the surface waviness and metal erosion of the former were higher. They also observed that the jet-impinging diameter was larger when the jet was unsubmerged compared with when it was submerged, resulting in an increase in the channel width for a given depth.…”

Section: Introductionmentioning

confidence: 99%

Multi-response parametric optimisation of abrasive waterjet milling of Hastelloy C-276

Gopichand¹,

Sreenivasarao

2020

SN Appl. Sci.

View full text Add to dashboard Cite

Abrasive waterjet (AWJ) milling is a rapidly evolving research topic in the development of unconventional methods for machining high-strength materials without affecting their physical and thermal properties. It is considered as a promising technique for machining milling pockets in Hastelloy C-276. In the present study, the AWJ milling behaviour of Hastelloy C-276 was examined with the purpose of evaluating the performance parameters, namely the material removal rate and surface roughness (R a ). The considered input process parameters included the waterjet pressure, step over, traverse rate, and abrasive flow rate. The response surface methodology with a Box-Behnken design was used to perform the experiments, which involved 29 machining runs. Analysis of variance was used to identify the significant parameters of the machining process, and the optimal process parameter combination for achieving a high material removal rate and low surface roughness was established with the aid of response surface graphs. Multi-response optimisation based on grey relational analysis was also performed taking into consideration the overall output response. The waterjet pressure and traverse rate were identified as the primary determinants of the material removal rate, whereas the step over was the predominant factor of the surface roughness. The selected AWJ milling conditions based on grey relational analysis approach were examined using surface morphology, surface topography of milled pockets on Hastelloy C-276.

show abstract

Section: Introductionmentioning

confidence: 99%

Multi-response parametric optimisation of abrasive waterjet milling of Hastelloy C-276

Gopichand¹,

Sreenivasarao

2020

SN Appl. Sci.

View full text Add to dashboard Cite

show abstract

“…All experiments were performed under typical AWJM operation conditions [72][73][74] at a jet angle of 90˚, and an input water temperature of 12˚C. The conditions are shown in Table 2.2.…”

Section: 3mentioning

confidence: 99%

“…programmable nozzle movement allowing positional accuracy of ± 80 µm over a 30 cm length, was used to perform the edge-trimming experiments on the two composites. The AWJM apparatus was fitted with a micro-nozzle having a 128 µm diamond orifice and a 254 µm mixing tube diameter, producing a ~335 m footprint on a flat target surface at a SOD of 1 mm[65]. All experiments were conducted in air; i.e.…”

mentioning

confidence: 99%

Predicting Surface Roughness and Delamination When Abrasive Waterjet Machining Fiber Reinforced Polymer Composites

Schwartzentruber¹

2023

Preprint

View full text Add to dashboard Cite

The machining of composite materials is difficult because of their non-homogenous structure and their constituents commonly possess a high resistance to cutting. Abrasive waterjet machining (AWJM) is more attractive for composite substrates than conventional machining techniques because of its ability to rapidly machine a wide variety of materials with low reactionary forces on the workpiece, and without creating a heat-affected zone. However, AWJM is prone to producing variable surface roughness and delamination. This dissertation aimed to model these surface roughness and delamination mechanisms. The thesis presents 2D and 3D roughness models capable of predicting the surface roughness during abrasive waterjet (AWJ) trimming of composite substrates. The models were able to predict the measured surface roughness with an average error of 10% and 16%, for the 2D and 3D models, respectively. The thesis also presents experimental and numerical results characterizing the delamination when AWJ piercing and cutting a carbon-fiber/epoxy laminate. Fluid-structure interaction (FSI) models created to simulate the piercing process showed that interlaminar delamination was due to the hydraulic shock (‘water hammer’) associated with liquid jet impact. As expected, increased pressure and nozzle size resulted in ply debonding, and was experimentally verified using 3D x-ray micro-tomography. The composite anisotropy was found to produce an asymmetric shock loading along the liquid-solid interface, which contributed to the asymmetric delamination. The FSI model showed that delamination when cutting carbon-fiber/epoxy depended primarily on the normal interlaminar stress, with relatively large damage zones occurring ahead of the cutting front. This trend was also observed in x-ray micro-tomographs of an AWJ cut. The amount of delamination across different process parameters was also measured using a moisture uptake methodology, and showed that increase traverse speed, increased nozzle size, and decreased abrasive flow rate, increased delamination. Prediction and characterization of surface roughness and delamination when AWJM will allow further improvement of cut-surface finish and structural integrity of composite materials, respectively

show abstract

“…Some researchers focused on investigations of the disintegration of abrasive particles in the mixing process [36], others searched for new types of abrasive materials [37], others studied the recycled ones [38,39] or try to apply ice particles [40], as the most environmentally friendly abrasive. Some special applications like using the AWJ for sculpturing [41], micro-piercing [42] or micro-machining [43] bring new challenges for researchers dealing with water jetting. However, the studies of applications of AWJ on the "classical" materials like tiles [44], wood [45] or Hardox [46] can also bring about new knowledge.…”

Section: Introductionmentioning

confidence: 99%

Revised Model of Abrasive Water Jet Cutting for Industrial Use

Hlaváč

2021

Materials

View full text Add to dashboard Cite

Research performed by the author in the last decade led him to a revision of his older analytical models used for a description and evaluation of abrasive water jet (AWJ) cutting. The review has shown that the power of 1.5 selected for the traverse speed thirty years ago was influenced by the precision of measuring devices. Therefore, the correlation of results calculated from a theoretical model with the results of experiments performed then led to an increasing of the traverse speed exponent above the value derived from the theoretical base. Contemporary measurements, with more precise devices, show that the power suitable for the traverse speed is essentially the same as the value derived in the theoretical description, i.e., it is equal to “one”. Simultaneously, the replacement of the diameter of the water nozzle (orifice) by the focusing (abrasive) tube diameter in the respective equations has been discussed, because this factor is very important for the AWJ machining. Some applications of the revised model are presented and discussed, particularly the reduced forms for a quick recalculation of the changed conditions. The correlation seems to be very good for the results calculated from the present model and those determined from experiments. The improved model shows potential to be a significant tool for preparation of the control software with higher precision in determination of results and higher calculation speed.

show abstract

Abrasive waterjet micro-machining of channels in metals: Model to predict high aspect-ratio channel profiles for submerged and unsubmerged machining

Cited by 47 publications

References 21 publications

Multi-response parametric optimisation of abrasive waterjet milling of Hastelloy C-276

Multi-response parametric optimisation of abrasive waterjet milling of Hastelloy C-276

Predicting Surface Roughness and Delamination When Abrasive Waterjet Machining Fiber Reinforced Polymer Composites

Revised Model of Abrasive Water Jet Cutting for Industrial Use

Contact Info

Product

Resources

About