Abrasive water jet milling (AWJM) is a new way to perform controlled depth milling especially for hard materials, but it's not yet enough reliable because of large variety of process parameters and complex footprint geometries that are not well mastered. In order to master the milling device in AWJM, a deep study on the footprint of a single path of the cutting head should first be considered. The flow of the AWJ and the distribution of abrasive particles coming out of the jet are related to the profile measured on the footprint. In this study, experiments were made on titanium alloys specimen to compare several theoretical models to the measured profile of the footprint. This study establishes new models to fit the incision profile taking in consideration the behavior of the abrasive particles impacting the workpiece.Key words: Abrasive waterjet milling, incision, titanium alloy, process parameters, Gaussian model.
Nomenclature:a maximum depth parameter (mm) b width parameter (mm) b0.5 width at half of maximum depth (mm) b1 width parameter of first Gaussian part (mm) b2 width parameter of second Gaussian part (mm)
1-IntroductionAbrasive water jet (AWJ) acquired a great technological progress in the last decades. Its popularity has changed considerably thanks to its high pressure joined to the flow of abrasive particles allowing the cut of any type of material. AWJ is a non-conventional machining process in which a mixture of abrasive particles and water at very high pressure is converted into a high velocity jet to cut various materials that can range from brittle to ductile materials. The water jet cutting is considered as a very efficient manufacturing process involving small amounts of heat transferred to the workpiece. Thereby, metal parts made by AWJ process does not change the crystal structure usually caused by the heat generated with other methods of material removal such as laser cutting, EDM (Electrical Discharge Machining), milling machining... The AWJ has become an emerging technology with versatile features.Controlled depth milling appeared in the early 1990s and is intended for the production of pockets. Until now this process has not yet been mastered, especially for hard materials. In order to comprehend the milling of pockets in AWJ, milling incisions (representing a single path of the cutting head on the workpiece) should firstly be studied. Several works were established to investigate this technology, F. CENAC studied controlled depth milling on Composites and aluminum alloys [C1] [CC1], and G. FLOWER worked on Titanium alloys [Fo1]. In their studies masks were used to avoid irregularities in the bottom of the milled pocket. In the case of maskless pocket milling in AWJ, a precise study on the impinging water jet is required to understand the mechanisms of abrasive and water flow machining and their impact on the workpiece.Article 039-pp-9
474Research in Interactive Design -Vol. 4 F. CENAC showed in his studies [C1] that the velocity profile of water particles going out of the cu...