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.

Numerical Simulation and Experimental Validation of Pure Water Jet Machining of Ti-6Al-4V

2020 ◽  
Author(s):  
Greg Pasken ◽  
J. Ma ◽  
Muhammad P. Jahan ◽  
Shuting Lei
Keyword(s):  
Predictive Modeling ◽  
Metal Cutting ◽  
Removal Rate ◽  
Pure Water ◽  
Surface Profile ◽  
Predictive Modelling ◽  
Water Jet ◽  
The Other ◽  
Orifice Diameter ◽  
Cutting Processes

Abstract The most common problem when machining titanium using traditional metal cutting processes is that tools rapidly wear out and need to be replaced. This study examines the ability of a pure water jet to machine Ti-6Al-4V via simulations using ABAQUS’s Smoothed Particle Hydrodynamics (SPH). These simulations are then validated experimentally at two pressures, 138 MPa and 317 MPa. Using a Maxiem water jet built by Omax, experiments are conducted by creating a series of 5 lines that are 5 inches (127 mm) long placed 0.5 inches (12.7 mm) apart on a 1 mm thick Ti-6Al-4V workpiece. Predictive modeling is also conducted using the two additional pressures 400 MPa and 621 MPa as well as three orifice diameters 0.254 mm, 0.3556 mm, and 0.4572 mm. The simulations are validated at both pressures and had a percent error less than 2.6% which were within the standard deviation of the experimental results. The predictive modeling indicates that the pressures above 317 MPa create a near identical percent increase from the orifice diameter but the kerf has a more noticeable decrease in width of cut as the pressure increases. The 138 MPa has the smoothest surface profile compared to the other pressures. The volume of removed material decreases as the pressure increases but the material removal rate (MRR) increases as the pressure increases. This is due to the velocity of the water increasing as the pressure increases causing a lower run time. The 621 MPa is the best pressure to machine Ti-6Al-4V as it has a better MRR than the other pressures used in the predictive modelling.

Simulation and experimental results of an unmanned towed system

2020 ◽  
Vol 234 (15) ◽  
pp. 2167-2185
Author(s):  
Nghia Huynh ◽  
Carlos Montalvo
Keyword(s):  
Flight Dynamics ◽  
Experimental Results ◽  
State Model ◽  
Small Scale ◽  
Experimental Setup ◽  
Pd Controller ◽  
Full State ◽  
Main Driver ◽  
Simulation Results ◽  
Small Instrument

This report investigates the flight dynamics of a small-scale (2 ft) towed system using a quadcopter and actively controlled payload. A towed system includes a main driver to propel the system forward connected to a payload via a tether. The towed system here is unique, and in that the driver is a scratch built quadcopter while the payload is also a scratch built actively controlled aircraft. The payload is designed to carry a small instrument that must be sufficiently far away from all interferences created by a quadcopter. A fully non-linear full state model is created and utilized to reveal that oscillations in the payload are decreased with the introduction of a PD controller on the payload. An experimental setup is built to validate simulation results. Experiments show that an actively controlled payload can decrease the attitude oscillations of the payload.

scholarly journals Hydrodynamic Analysis-Based Modeling and Experimental Verification of a New Water-Jet Thruster for an Amphibious Spherical Robot

Sensors ◽  
2019 ◽  
Vol 19 (2) ◽  
pp. 259 ◽  
Author(s):  
Xihuan Hou ◽  
Shuxiang Guo ◽  
Liwei Shi ◽  
Huiming Xing ◽  
Yu Liu ◽  
...  
Keyword(s):  
Motion Control ◽  
Axial Flow ◽  
Maximum Error ◽  
Water Jet ◽  
Experimental Results ◽  
Hydrodynamic Characteristics ◽  
Spherical Robot ◽  
Basic Framework ◽  
Oblique Flow ◽  
Simulation Results

Thrusters are the bottom actuators of the amphibious spherical robot, and play an important role in the motion control of these robots. To realize accurate motion control, a thrust model for a new water-jet thruster based on hydrodynamic analyses is proposed in this paper. First, the hydrodynamic characteristics of the new thruster were numerically analyzed using computational fluid dynamics (CFD) commercial software CFX. The moving reference frame (MRF) technique was utilized to simulate propeller rotation. In particular, the hydrodynamics of the thruster were studied not only in the axial flow but also in oblique flow. Then, the basic framework of the thrust model was built according to hydromechanics theory. Parameters in the basic framework were identified through the results of the hydrodynamic simulation. Finally, a series of relevant experiments were conducted to verify the accuracy of the thrust model. These proved that the thrust model-based simulation results agreed well with the experimental results. The maximum error between the experimental results and simulation results was only 7%, which indicates that the thrust model is precise enough to be utilized in the motion control of amphibious spherical robots.

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.

An Experimental Investigation of a Heated Two-Dimensional Water Jet Discharge Into a Moving Stream

1974 ◽  
Vol 96 (3) ◽  
pp. 273-278 ◽  
Author(s):  
A. J. Patton ◽  
F. L. Test ◽  
W. M. Hagist
Keyword(s):  
Experimental Investigation ◽  
Water Jet ◽  
Experimental Results ◽  
Temperature Profiles ◽  
Two Dimensional ◽  
Water Stream ◽  
Water Jets ◽  
Temperature Decay ◽  
Jet Trajectory ◽  
Jet Characteristics

The experimental results are presented for a study of the behavior of heated and unheated two-dimensional water jets injected from the bottom of a moving water stream. The jet characteristics are described in terms of velocity and temperature profiles, velocity and temperature decay, jet width, jet trajectory, and jet turbulence. The conditions which favor the formation of an upstream thermal wedge are investigated.

Operation of Water Jet System in a Sandstone Quarry and its Impact on Production

2013 ◽  
Vol 308 ◽  
pp. 19-24
Author(s):  
Roman Gryc ◽  
Libor M. Hlaváč ◽  
Milan Mikoláš ◽  
Vilém Mádr ◽  
Ivan Wolf ◽  
...  
Keyword(s):  
Pure Water ◽  
Water Jet ◽  
Basic Information ◽  
System Operation ◽  
Water Jets ◽  
Cutting System

The experiments with pure water jets were performed both in laboratory and in a quarry. The basic information about water jet system operation in quarry conditions has been acquired and some relations between data from a quarry and the laboratory ones have been determined. The efficiency of the cutting system in quarry conditions is considered and discussed.

Experimental Study on the Specific Heat Capacity Measurement of Water-Based Al2O3-Cu Hybrid Nanofluid by using Differential Thermal Analysis Method

2019 ◽  
Vol 15 ◽  
Author(s):  
Andaç Batur Çolak ◽  
Oğuzhan Yıldız ◽  
Mustafa Bayrak ◽  
Ali Celen ◽  
Ahmet Selim Dalkılıç ◽  
...  
Keyword(s):  
Heat Capacity ◽  
Specific Heat ◽  
Specific Heat Capacity ◽  
Thermophysical Properties ◽  
Volume Concentration ◽  
Pure Water ◽  
Heat Capacity Measurement ◽  
Experimental Results ◽  
Hybrid Nanofluid ◽  
Capacity Measurement

Background: Researchers working in the field of nanofluid have done many studies on the thermophysical properties of nanofluids. Among these studies, the number of studies on specific heat are rather limited. In the study of the heat transfer performance of nanofluids, it is necessary to increase the number of specific heat studies, whose subject is one of the important thermophysical properties. Objective: The authors aimed to measure the specific heat values of Al2O3/water, Cu/water nanofluids and Al2O3-Cu/water hybrid nanofluids using the DTA method, and compare the results with those frequently used in the literature. In addition, this study focuses on the effect of temperature and volume concentration on specific heat. Method: The two-step method was used in the preparation of nanofluids. The pure water selected as the base fluid was mixed with the Al2O3 and Cu nanoparticles and Arabic Gum as the surfactant, firstly mixed in the magnetic stirrer for half an hour. It was then homogenized for 6 hours in the ultrasonic homogenizer. Results: After the experiments, the specific heat of nanofluids and hybrid nanofluid were compared and the temperature and volume concentration of specific heat were investigated. Then, the experimental results obtained for all three fluids were compared with the two frequently used correlations in the literature. Conclusion: Specific heat capacity increased with increasing temperature, and decreased with increasing volume concentration for three tested nanofluids. Cu/water has the lowest specific heat capacity among all tested fluids. Experimental specific heat capacity measurement results are compared by using the models developed by Pak and Cho and Xuan and Roetzel. According to experimental results, these correlations can predict experimental results within the range of ±1%.

Simulation of carding condensing process

2021 ◽  
pp. 004051752098812
Author(s):  
Xixi Qian ◽  
Yuanying Shen ◽  
Qiaoli Cao ◽  
Jun Ruan ◽  
Chongwen Yu
Keyword(s):  
Experimental Results ◽  
Simulation Results ◽  
Carding Machine ◽  
The Web

A simulation describing the fiber movement during the condensation was conducted, and the effect of the condensation in the carding machine was studied. The simulation results showed that the condensation has the blending and the evening effect on the condensed sliver, which can be explained by the fiber rearrangement. Moreover, the increasing web width and the decreasing condensing length can result in a more uniform sliver. Further, the evening effect of the web width on the web was verified by experiments. The simulation results were in general agreement with the experimental results.

Wave Energy Hyperbaric Device for Electricity Production

2007 ◽  
Author(s):  
Segen F. Estefen ◽  
Paulo Roberto da Costa ◽  
Eliab Ricarte ◽  
Marcelo M. Pinheiro
Keyword(s):  
Power Generation ◽  
Wave Energy ◽  
Experimental Results ◽  
Electricity Production ◽  
Scale Model ◽  
Small Scale ◽  
Regular Waves ◽  
Hyperbaric Chamber ◽  
Small Scale Model

Wave energy is a renewable and non-polluting source and its use is being studied in different countries. The paper presents an overview on the harnessing of energy from waves and the activities associated with setting up a plant for extracting energy from waves in Port of Pecem, on the coast of Ceara State, Brazil. The technology employed is based on storing water under pressure in a hyperbaric chamber, from which a controlled jet of water drives a standard turbine. The wave resource at the proposed location is presented in terms of statistics data obtained from previous monitoring. The device components are described and small scale model tested under regular waves representatives of the installation region. Based on the experimental results values of prescribed pressures are identified in order to optimize the power generation.

Numerical Study of Methane and Air Combustion Inside Heat-Recirculating Combustors

2013 ◽  
Author(s):  
Yanxia Li ◽  
Zhongliang Liu ◽  
Yan Wang ◽  
Jiaming Liu
Keyword(s):  
Gas Flow ◽  
Numerical Study ◽  
Convection Heat Transfer ◽  
Central Area ◽  
Small Scale ◽  
Inlet Velocity ◽  
Strong Convection ◽  
Simulation Results ◽  
Lean Fuel ◽  
Set Up

A numerical model on methane/air combustion inside a small Swiss-roll combustor was set up to investigate the flame position of small-scale combustion. The simulation results show that the combustion flame could be maintained in the central area of the combustor only when the speed and equivalence ratio are all within a narrow and specific range. For high inlet velocity, the combustion could be sustained stably even with a very lean fuel and the flame always stayed at the first corner of reactant channel because of the strong convection heat transfer and preheating. For low inlet velocity, small amounts of fuel could combust stably in the central area of the combustor, because heat was appropriately transferred from the gas to the inlet mixture. Whereas, for the low premixed gas flow, only in certain conditions (Φ = 0.8 ～ 1.2 when ν0 = 1.0m/s, Φ = 1.0 when ν0 = 0.5m/s) the small-scale combustion could be maintained.

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