Adaptive speed control for waterjet milling in pocket corners

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

doi:10.1007/s00170-019-03546-z

Cited by 10 publications

(5 citation statements)

References 17 publications

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“…~0.5, and moreover, highly rounded corners will result. This agrees with the results of Bui et al who showed a speed bump type defect on the corners of flat pockets [106]. Various path strategies have been developed to overcome similar issues when performing AWJM around corners to compensate for the non-uniform nozzle kinematics [92].…”

Section: Unmasked Awjm Of Molds In Ss316 Containing Non-intersecting ...supporting

confidence: 90%

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Azarsa¹

2023

Preprint

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Many advanced engineering materials are machined using abrasive water jets, a non-traditional machining method that has certain advantages compared to other approaches. This dissertation aims at developing methodologies to use abrasive water and slurry jets to micro-machine free-standing structures for heat sink and microfluidics applications. The first aim was to fabricate high aspect ratio free-standing structures with a minimum distance between each other that would lead to maximum heat transfer performance in heat sinks. The effect of machining process parameters on the quality of the resulting free-standing structures was studied. It was demonstrated that high-quality free-standing structures with aspect ratios of more than 40 to be used as fins in heat sinks could be fabricated. There is an increasing demand for metallic micro-molds that can be used for inexpensive mass production of polymeric microfluidic chips. Therefore, the feasibility of using abrasive water jet micro-machining (AWJM) and abrasive slurry jet micro-machining (ASJM) to fabricate such micro-molds was studied. Jet raster scans under various combinations of process parameters were used in order to machine micro-pockets containing free-standing structures, representing molds for casting microfluidic chips with channel networks. The optimum process parameters and material were determined in order to fabricate the molds with the best possible surface finish. Because unmasked machining could not be used to fabricate molds with sharp-edged intersecting features, a hybrid AWJM/ASJM masked machining technique was introduced. By careful selection of the process parameters, high quality molds with both single and intersecting free-standing structures at multiple heights could be fabricated, thus making three-dimensional microfluidic chip mold fabrication feasible. Finally, a new method of mold fabrication that utilized water jet cutting technology to cut free-standing structures out of mild steel sheets, to be used as a mold for PDMS casting, was developed. This enabled 3D features having very abrupt changes in depth with almost 90o angles for use in microfluidic devices. As a proof-of-concept, a polydimethylsiloxane (PDMS) chip was made and tested. It was shown that this alternative approach to create microfluidic molds is versatile and may find utility in reducing the cost and complexity involved in fabricating 3D features in microfluidic devices.

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Section: Unmasked Awjm Of Molds In Ss316 Containing Non-intersecting ...supporting

confidence: 90%

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Azarsa¹

2023

Preprint

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“…All input parameters are selected as it was done in previous works [10,13] which play the role of the setting parameters in a given machine configuration. In addition, the results from previous works [10,13,14] has demonstrated the efficiency of the model to predict the geometrical characteristics of the kerf profile of both the elementary pass and pocket for various values of traverse speed. The present work only consider the influence of the jet inclination angle (α) on the milling process.…”

Section: Methodsmentioning

confidence: 85%

Develop Model for Controlled Depth Milling by Abrasive Water Jet of Ti6Al4V at Jet Inclination Angle

Bui

Gilles

Cohen

et al. 2021

Lecture Notes in Mechanical Engineering

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Abrasive water jet machining (AWJM) is an interesting solution for the production of shallow pockets in metal sheets made of titanium alloys. Indeed, it produces low cutting forces and heat generation and prevents deformation of these parts after machining. In addition, it has the advantage of only using two raw materials: sand and water. It is possible to generate pocket edges with an imposed geometry using AWJM, but it is necessary to tilt the axis of the jet. The material removal mechanism is then a function of the inclination angle. The presented study propose an improved model for modelling the pocket profile in TiAl6V parts. The experimental results shows that the model is efficient as the precision is around 5%.

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“…The presently used relationships between the information signal and tool wear are phenomenological, frequently without quantitative substantiation. The research issues have been investigated in the context of machine learning for predictive maintenance in milling [35], development of a new algorithm for online tool wear control [36], development of an innovative, intelligent machine tool [37], adaptive speed control for waterjet milling [38], and model-free adaptive predictive control for CNC [39]. Therefore, at the present level of the development of material processing by cutting, it is necessary to determine the degree of correlation between the sound generated during the cutting process, i.e., one of the promising information signals, the wear of the cutter, and the workpiece surface roughness.…”

Section: Adaptive Control Methodsmentioning

confidence: 99%

Method of Using the Correlation between the Surface Roughness of Metallic Materials and the Sound Generated during the Controlled Machining Process

et al. 2022

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The article aims to use the generated sound as operational information needed for adaptive control of the metalworking process and early monitoring and diagnosis of the condition of the machined materials using a newly introduced surface roughness quality index due to the sound-controlled machining process. The object of the measurement was correlation between the sound intensity generated during cutting and the material parameters of the machined surface, i.e., the roughness of the machined surface and the degree of wear of the cutting tool. The roughness was measured during longitudinal turning of a steel billet with a P25 insert made of 12X18H10T steel and a T15K6 cutting insert made of a titanium, cobalt, and tungsten group alloy. The correlation between the sound and roughness of the machined surface was 0.93, whereas between the sound and wear of the cutting tool was 0.93. The correlation between sound and tool wear in the experiment with P25 and T15K6 cutting inserts and the correlation between sound and roughness is positive.

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Adaptive speed control for waterjet milling in pocket corners

Cited by 10 publications

References 17 publications

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Develop Model for Controlled Depth Milling by Abrasive Water Jet of Ti6Al4V at Jet Inclination Angle

Method of Using the Correlation between the Surface Roughness of Metallic Materials and the Sound Generated during the Controlled Machining Process

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