Precision comparison of analytical and statistical-regression models for AWJ cutting

Hlaváč, Libor M.; Krajcarz, Daniel; Hlaváčová, Irena M.; Spadło, S.

doi:10.1016/j.precisioneng.2017.05.002

Cited by 28 publications

(11 citation statements)

References 38 publications

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“…In addition, RSM allows us to generate different contour diagrams or response surfaces from a second order polynomial Equation (1). There are several articles that have implemented this type of equation in order to develop the results obtained in the experiments carried out [31,33,34].…”

Section: Reinforcementmentioning

confidence: 99%

Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

et al. 2019

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Carbon fiber-reinforced thermoplastics (CFRTPs) are materials of great interest in industry. Like thermosets composite materials, they have an excellent weight/mechanical properties ratio and a high degree of automation in their manufacture and recyclability. However, these materials present difficulties in their machining due to their nature. Their anisotropy, together with their low glass transition temperature, can produce important defects in their machining. A process able to machine these materials correctly by producing very small thermal defects is abrasive waterjet machining. However, the dispersion of the waterjet produces a reduction in kinetic energy, which decreases its cutting capacity. This results in an inherent defect called a kerf taper. Also, machining these materials with reduced thicknesses can increase this defect due to the formation of a damage zone at the beginning of cut due to the abrasive particles. This paper studies the influence of cutting parameters on the kerf taper generated during waterjet machining of a thin-walled thermoplastic composite material (carbon/polyurethane, C/TPU). This influence was studied by means of an ANOVA statistical analysis, and a mathematical model was obtained by means of a response surface methodology (RSM). Kerf taper defect was evaluated using a new image processing methodology, where the initial and final damage zone was separated from the kerf taper defect. Finally, a combination of a hydraulic pressure of 3400 bar with a feed rate of 100 mm/min and an abrasive mass flow of 170 g/min produces the minimum kerf taper angle.

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Section: Reinforcementmentioning

confidence: 99%

Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

et al. 2019

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“…The main benefit of the presented theoretical base is quite simple and relatively precise transformation of knowledge from the known and proven stages into new ones. Such transformations were presented during precision investigations in [ 62 , 63 , 64 ]. One of the most important is the transformation of the traverse speed limit for the different pressure and the abrasive mass flow rate.…”

Section: Model Of the Awj Transformed From The Wj Modelmentioning

confidence: 99%

Revised Model of Abrasive Water Jet Cutting for Industrial Use

Hlaváč

2021

Materials

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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.

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“…One of the most common manufacturing processes is the response surface methodology (RSM). RSM is extensively used in an analytical and industrial application like turning [32,33], milling [34], welding [35], grinding [36], and erosion machining [37]. Ghodsiyeh et al [38] used RSM to optimize the wire electrical discharge machining of the titanium alloy Ti-6Al-4 V. Presented results indicated that the pulse time had the highest impact on surface roughness, whilst discharge current had the same role for the wire wear ratio and white layer thickness.…”

Section: Introductionmentioning

confidence: 99%

Multi-Response Optimization of Electrical Discharge Machining Using the Desirability Function

2019

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Electrical discharge machining (EDM) is a modern technology that is widely used in the production of difficult to cut conductive materials. The basic problem of EDM is the stochastic nature of electrical discharges. The optimal selection of machining parameters to achieve micron surface roughness and the recast layer with the maximal possible value of the material removal rate (MRR) is quite challenging. In this paper, we performed an analytical and experimental investigation of the influence of the EDM parameters: Surface integrity and MRR. Response surface methodology (RSM) was used to build empirical models on the influence of the discharge current I, pulse time ton, and the time interval toff, on the surface roughness (Sa), the thickness of the white layer (WL), and the MRR, during the machining of tool steel 55NiCrMoV7. The surface and subsurface integrity were evaluated using an optical microscope and a scanning profilometer. Analysis of variance (ANOVA) was used to establish the statistical significance parameters. The calculated contribution indicated that the discharge current had the most influence (over the 50%) on the Sa, WL, and MRR, followed by the discharge time. The multi-response optimization was carried out using the desirability function for the three cases of EDM: Finishing, semi-finishing, and roughing. The confirmation test showed that maximal errors between the predicted and the obtained values did not exceed 6%.

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Precision comparison of analytical and statistical-regression models for AWJ cutting

Cited by 28 publications

References 38 publications

Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

Revised Model of Abrasive Water Jet Cutting for Industrial Use

Multi-Response Optimization of Electrical Discharge Machining Using the Desirability Function

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