Numerical Modeling of a Pure Water Jet Machining of Ti-6Al-4V and Al 6061-T6 Using ABAQUS and Smoothed Particle Hydrodynamics

2018 ◽  
Author(s):  
Gregory Pasken ◽  
J. Ma ◽  
M. McQuilling ◽  
Muhammad P. Jahan
Keyword(s):  
Pure Water ◽  
Water Jet ◽  
Damage Initiation ◽  
Al 6061 ◽  
Hard Materials ◽  
Nano Scale ◽  
Water Jets ◽  
Water Jet Cutting ◽  
Particle Hydrodynamics ◽  
Smoothed Particle

Pure water jets are not as effective as abrasive water jets for cutting hard materials at large scales. However, for nano-scale cutting, water jet cutting with abrasives is not possible because the abrasive particles are typically in the micron range which is three orders of magnitude larger than sizes to be cut. A pure water jet at the nano-scale might be a viable option. To ensure that it is possible to cut metals using a pure water jet, simulations at millimeter scale are conducted before downscaling to nano-scale. These simulations, using the smooth particle hydrodynamics (SPH) feature of ABAQUS, are conducted using two plate materials, Al 6061 and Ti-6Al-4V, with identical plate dimensions. The water jet is simulated via SPH, while the plate is modeled using standard FE methods. The water velocity and nozzle diameter are chosen to match those commonly used by companies employing water jets. Both the Al 6061 and Ti-6Al-4V simulations achieve convergence. Simulation results for both materials show damage on the surface and material removal. The top layer is removed in both cases as well as damage initiation is observed on the next layer of elements. These numerical results suggest that it is possible to use a pure water jet to cut two different metals. This research lays the foundation to use a pure water jet to conduct nanomachining of hard materials.

scholarly journals Design and Simulation of Nozzle for Pure Water Jet Portable Cutting Tool

2019 ◽  
Vol 8 (12S2) ◽  
pp. 703-706
Keyword(s):  
Pressure Drop ◽  
Cross Sections ◽  
Pure Water ◽  
Water Jet ◽  
Element Analysis ◽  
Cutting Machine ◽  
Water Jet Cutting ◽  
Computational Fluid Dynamics Cfd ◽  
Flow Through ◽  
The Impact

A pure water jet at subsonic speed provides an opportunity for application in cutting soft material with the advantage of not contaminating the workpiece. Inside the nozzle, water is flowing through various cross sections, which lead to pressure drop and loss of energy. This requires a nozzle with a design that causes minimum pressure drop. In this work, Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) were used to analyse the flow through five different nozzles. For each nozzle, the pressures of 10 MPa, 20 MPa and 30 MPa were applies at the inlet. For the inlet pressure of 10 MPa, the highest outlet velocity us 136.12 m/s at the pressure of 9.261 MPa. The impact pressure at stand distance of 0.5 mm and 1.0 mm were 8.26 MPa and 8.02 MPa, respectively. For this nozzle, the Factor of Safety for 10 MPa, 20 MPa and 30 MPa were 6.4, 3.2 and 2.961, respectively. The findings are relevant to the development of pure water jet cutting machine

scholarly journals Numerical Simulation of Ti-Based Metallic Glasses as Whipple Shield Bumper by Smoothed Particle Hydrodynamics Methods

2020 ◽  
Vol 993 ◽  
pp. 826-835
Author(s):  
Wei Qi Tang ◽  
Kun Zhang ◽  
Yan Sen Li ◽  
Yang Wang ◽  
Ya Ting Zhang ◽  
...  
Keyword(s):  
Metallic Glasses ◽  
Smoothed Particle Hydrodynamics ◽  
Areal Density ◽  
Hypervelocity Impacts ◽  
Al 6061 ◽  
Ejection Angle ◽  
Particle Hydrodynamics ◽  
Smoothed Particle ◽  
Debris Cloud ◽  
Whipple Shield

The debris clouds produced by hypervelocity impacts on Ti-based metallic glasses (Ti-MGs) and Al-6061-T6 bumper were studied by smoothed particle hydrodynamics (SPH) methods. The change of the vanguard shape, dispersion and ejection angle were also obtained with the same bumper thickness to the projectile-diameter ratio (h/d). For the same h/d valve, the debris cloud of Ti-MGs bumper had a more widely dispersion and ejection angle than with Al-6061-T6 bumper; the vanguard velocity of Ti-MGs bumper was also lower than Al-6061-T6 bumper. Moreover, for the same bumper areal density, the vanguard of the debris cloud in MGs bumper was plane-shaped. This study demonstrates that Ti-MGs exhibit an excellent bumper protection performance, which asset can pave new paths for their further applications.

Numerical Simulation of High Speed Water Jet Erosion of Sand Bed Based on SPH

2014 ◽  
Vol 641-642 ◽  
pp. 304-308
Author(s):  
Fu Sheng Ni ◽  
De Yi Zhang ◽  
Hui Wang ◽  
Lei Gu
Keyword(s):  
High Speed ◽  
Pressure Field ◽  
Water Jet ◽  
Target Distance ◽  
Sph Method ◽  
Simulation Process ◽  
Particle Hydrodynamics ◽  
Smoothed Particle ◽  
Jet Velocity ◽  
Key Techniques

Water jet technology is widely used in dredging engineering. Since there will be large deformation of sand bed during erosion by water jet, the calculation mesh will be distorted seriously and lead to simulation failure. In order to solve the problem, the Smoothed Particle Hydrodynamics (SPH) method was used to simulate the dynamic process of high speed water jet erosion of sand bed. The simulation process and key techniques were discussed, the effect of water jet velocity and water jet target distance on the depth of eroded pit was studied. The results show that SPH could describe the process intuitively and the evolution of particle velocity field and sand bed pressure field could be shown clearly. The depth of the pit varies with time linearly. The decrease of water jet target distance and the increase of the water jet velocity deepen the eroded pit.

Numerical Study of Unsteady Behavior of Cloud Cavitation by Smoothed Particle Hydrodynamics

2020 ◽  
Author(s):  
Takahiro Ushioku ◽  
Hiroaki Yoshimura
Keyword(s):  
Numerical Analysis ◽  
Multiphase Flow ◽  
Smoothed Particle Hydrodynamics ◽  
Collective Motion ◽  
Numerical Study ◽  
Water Jet ◽  
Lagrangian Description ◽  
Cloud Cavitation ◽  
Particle Hydrodynamics ◽  
Smoothed Particle

Abstract Cavitation generates a portion of cavities called a cavitation cloud, which performs a collective unsteady motion of repeating the process of growth and collapse. In particular, it is considered that a high-pressure shock wave propagates associated with the collapse. In order to understand such unsteady behaviors of the cavitation cloud, much effort has been made for the numerical analysis of internal flows of the cavitation cloud. However, it is not clear how such a cavitation cloud can be identified as a physical entity nor how its unsteady collective motion can be elucidated in the context of the multiphase fluid flow. In this study, we make a two-dimensional numerical analysis of the multiphase flow of the submerged bubbly water jet injecting into still water through a nozzle. To model the bubbly water jet, we employ the mixture model of liquids and gases, and we utilize the Smoothed Particle Hydrodynamics method for the numerical analysis of the unsteady flows in Lagrangian description. Finally, in order to clarify the unsteady behaviors of the cloud cavitation, we show how the cavitation cloud can be generated in the context of velocity fields in the multiphase flow and in particular, we clarify how twin vortices induced by the water jet play an essential role in the expansion and shrinkage of the cloud.

Numerical Simulation of Pure Water Jet Machining of Al 6061-T6 With Experimental Validation

2019 ◽  
Author(s):  
Greg Pasken ◽  
Jianfeng Ma ◽  
Muhammad P. Jahan ◽  
Shuting Lei
Keyword(s):  
Pure Water ◽  
Water Jet ◽  
Experimental Results ◽  
Inlet Pressure ◽  
Orifice Diameter ◽  
Small Scale ◽  
Machining Parameters ◽  
Water Jets ◽  
Small Scales ◽  
Simulation Results

Abstract Pure water jets are not as effective as abrasive water jets for cutting hard materials at large scales. Pure water jets can have kerfs as small as 0.076 mm, which is approximately the width of a human hair. This allows for small detailed cuts on workpiece material [1]. Research into using pure water jet to machine aluminum at small scales is important, as this will allow small scale and precision machining of the work piece material. At micro scales, water jet cutting with typical abrasives is not possible because the abrasive particles are typically in the micron range which is around the size of the cut. At small scales a pure water jet is more effective than abrasive water jet machining, as special nanometer size abrasives would be needed at small scales. A pure water jet only needs the correct size orifice to conduct machining at the small scale. These are the reasons why this study uses a pure water jet to conduct small scale machining of aluminum. This study investigates the use of ABAQUS’s Smoothed Particle Hydrodynamics to simulate pure water jet machining of metals and compares the simulation results of a water jet machining of Al6061-T6 to experimental results using the same material. The simulation results compare favorably to experimental results with only 2.81% error in the width of the cut. The predictive FEM modeling is then conducted for other combinations of machining parameters (orifice diameter and inlet pressure). It is found that orifice diameter and inlet pressure have substantial influence on the width and depth of cut. The results of the study open new possibilities for machining metals using a pure water jet at the micrometer scale and at smaller scales.

scholarly journals Comparative Study on Violent Sloshing with Water Jet Flows by Using the ISPH Method

Water ◽  
2019 ◽  
Vol 11 (12) ◽  
pp. 2590 ◽  
Author(s):  
Hua Jiang ◽  
Yi You ◽  
Zhenhong Hu ◽  
Xing Zheng ◽  
Qingwei Ma
Keyword(s):  
Practical Importance ◽  
Excitation Frequency ◽  
Water Jet ◽  
Liquid Sloshing ◽  
Jet Flows ◽  
Incompressible Sph ◽  
Particle Hydrodynamics ◽  
Smoothed Particle ◽  
The Impact ◽  
Violent Sloshing

The smoothed particle hydrodynamics (SPH) method has been playing a more and more important role in violent flow simulations since it is easy to deal with the large deformation and breaking flows from its Lagrangian particle characteristics. In this paper, the incompressible SPH (ISPH) method was used to simulate the liquid sloshing in a 2D tank with water jet flows. The study compares the liquid sloshing under different water jet conditions to analyze the effects of the excitation frequency and the water jet on impact pressure. The results demonstrate that the water jet flows can significantly affect the impact pressures on the wall caused by violent sloshing. The main purpose of the paper is to test the ISPH ability for this study and some useful regulars that are obtained from different numerical cases and study the effect of their practical importance.

The Metal Sheets Processed by AWJ. Analysis of the Surface Quality

2013 ◽  
Vol 837 ◽  
pp. 201-205 ◽  
Author(s):  
Carol Schnakovszky ◽  
Eugen Herghelegiu ◽  
Nicolae Catalin Tampu
Keyword(s):  
Surface Quality ◽  
High Speed ◽  
Experimental Tests ◽  
Water Jet ◽  
Machining Process ◽  
Abrasive Water Jet ◽  
Hard Materials ◽  
Water Jet Cutting ◽  
Metal Sheets

Abrasive water jet (AWJ) is a nonconventional machining process in which abrasive grains in a high-speed water jet collide with the sample and erode it. This technology has been developed as an alternative to the conventional processes in order to facilitate the processing of hard materials as stainless steel, titanium alloys, composite materials, etc. However, it is not limited only to hard materials, since it has been successfully applied to process softer materials as aluminum, copper, plastics. Also, the abrasive water jet technology can be used both, to process thin metal sheets and plates since it offers many advantages such as: good surface quality, no thermal distortions, minimal burrs, low machining force, high flexibility. The aim of the current paper was to study the surfaces quality of samples made by aluminium, A1050, processed by AWJ in case of using different working regimes. The experimental tests have been performed on the Hydro-jet Eco 0615 water jet cutting machine. The parameters that have been varied were pressure, feed rate, abrasive quantity, distance between the cutting head and working sample while the diameter of focusing tube and diameter of water nozzle have been kept constant. The parameters taken into account to quantify the quality of the processed surface were those defined in the ISO/WD/TC 44 N 1770 standard (fig. 1): width of the processed surface at the jet inlet (Li), width of the processed surface at the jet outlet (Lo), deviation from perpendicularity (u), inclination angle (α) and roughness (Ra).

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