Development of ice abrasive waterjet cutting technology

2017 ◽  
Vol 2 (81) ◽  
pp. 76-84
Author(s):  
J. Valentinčič ◽  
A. Lebar ◽  
I. Sabotin ◽  
P. Drešar ◽  
M. Jerman
Keyword(s):  
High Speed ◽  
Power Plants ◽  
Water Jet ◽  
Abrasive Waterjet ◽  
Abrasive Water Jet ◽  
Influence Of Process Parameters ◽  
Cutting Head ◽  
Ice Particles ◽  
Main Challenge ◽  
Awj Cutting

Purpose: Abrasive water jet (AWJ) cutting uses mineral abrasive to cut practically all materials. In ice abrasive water jet (IAWJ) cutting, the ice particles are used as abrasive. IAWJ is under development with the aim to bridge the gap in productivity between the abrasive water jet (AWJ) and water jet (WJ) cutting. It is clean and environmentally friendlier in comparison with AWJ, while its cutting efficiency could be better than WJ. Design/methodology/approach: The main challenge is to provide very cold and thus hard ice particles in the cutting zone, thus cooling the water under high pressure is utilized. Further on, two approaches to obtain ice particles in the water are studied, namely generation of ice particles in the cutting head and generation of ice particles outside of the cutting head and adding them to the jet similar as in AWJ technology. In this process it is essential to monitor and control the temperature occurring in the system. Findings: To have ice particles with suitable mechanical properties in the cutting process, the water have to be precooled, ice particles generated outside the cutting head and later added to the jet. The results show that, contrary to the common believe, the water temperature is not significantly changed when passing through the water nozzle. Research limitations/implications: The presence of ice particles was only indirectly identified. In the future, a special high speed camera will be used to study the influence of process parameters on ice particle distribution. Practical implications: IAWJ technology produces much less sludge (waste abrasive and removed workpiece material mixed with water) than AWJ technology which is beneficial in e.g. disintegration of nuclear power plants. IAWJ technology has also great potential in the food and medical industries for applications, where bacteria growth is not desired. Originality/value: The paper presents the latest achievements of IAWJ technology.

scholarly journals Research into the Disintegration of Abrasive Materials in the Abrasive Water Jet Machining Process

2021 ◽  
Author(s):  
Andrzej Perec
Keyword(s):  
Method Of Moments ◽  
High Speed ◽  
Water Jet ◽  
Machining Process ◽  
Abrasive Water Jet ◽  
Abrasive Particles ◽  
Cutting Head ◽  
Grain Distribution ◽  
Awj Cutting ◽  
Ward Method

The size and distribution of abrasive particles have a significant influence on the effectiveness of the cutting process by the high-speed abrasive water jet (AWJ). The paper deal with the abrasive materials disintegration intensity in AWJ cutting during the creation of the abrasive jet. An evaluation of the abrasive materials grabbed after forming in the cutting head was carried out and its grain distribution was evaluated. Used here the arithmetic, geometric and logarithmic method of moments and Folk and Ward method. The influence of abrasive concentration of abrasive materials as alluvial garnet, recycled garnet, corundum, and olivine on grain distribution was studied. A recovery analysis was also carried out and the recycling coefficient for each tested abrasive material was determined.

scholarly journals Research into the Disintegration of Abrasive Materials in the Abrasive Water Jet Machining Process

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3940
Author(s):  
Andrzej Perec
Keyword(s):  
High Speed ◽  
Water Jet ◽  
Machining Process ◽  
Abrasive Water Jet ◽  
Abrasive Material ◽  
Abrasive Particles ◽  
Cutting Head ◽  
Grain Distribution ◽  
Awj Cutting ◽  
Ward Method

The size and distribution of abrasive particles have a significant influence on the effectiveness of the cutting process by the high-speed abrasive water jet (AWJ). This paper deals with the disintegration intensity of abrasive materials in AWJ cutting during the creation of the abrasive jet. An evaluation of the abrasive materials was performed after forming in the cutting head was carried out and grain distribution was evaluated using the geometric and logarithmic Folk and Ward method. The influence of the abrasive concentration of abrasive materials such as alluvial garnet, recycled garnet, corundum, and olivine on grain distribution was studied. A recovery analysis was also carried out and the recycling coefficient was determined for each abrasive material tested.

Miniaturization of injection abrasive water jet machining process

2006 ◽  
Vol 220 (11) ◽  
pp. 1697-1705 ◽  
Author(s):  
H Orbanic ◽  
B Jurisevic ◽  
D Kramar ◽  
M Grah ◽  
M Junkar
Keyword(s):  
Water Jet ◽  
Heat Sinks ◽  
Machining Process ◽  
Process Efficiency ◽  
Abrasive Water Jet ◽  
Element Analysis ◽  
Abrasive Particles ◽  
Cutting Head ◽  
Simulation Based ◽  
Awj Cutting

This contribution presents the possibilities of applying abrasive water jet (AWJ) technology for multi-material micromanufacture. The working principles of injection and suspension AWJ systems are presented. Characteristics of this technology, such as the ability to machine virtually any kind of material and the absence of a relevant heat-affected zone, are given, especially those from which the production of microcomponents can benefit. A few attempts to miniaturize the AWJ machining process are described in the state-of-the-art preview. In order to develop and improve the AWJ as a microtool, a numerical simulation based on the finite element analysis is introduced to evaluate the effect of the size abrasive particles and the process efficiency of microsized AWJ. An ongoing project in which an improved mini AWJ cutting head is being developed, is presented. Finally, the possible fields of application are given, including a case study on the machining of miniaturized heat sinks.

scholarly journals Influence of Steel Structure on Machinability by Abrasive Water Jet

Materials ◽  
2020 ◽  
Vol 13 (19) ◽  
pp. 4424 ◽  
Author(s):  
Irena M. Hlaváčová ◽  
Marek Sadílek ◽  
Petra Váňová ◽  
Štefan Szumilo ◽  
Martin Tyč
Keyword(s):  
Heat Treatment ◽  
Surface Roughness ◽  
Mechanical Characteristics ◽  
Water Jet ◽  
Abrasive Waterjet ◽  
Abrasive Water Jet ◽  
Roughness Parameters ◽  
Steel Microstructure ◽  
Surface Roughness Parameters ◽  
Awj Cutting

Although the abrasive waterjet (AWJ) has been widely used for steel cutting for decades and there are hundreds of research papers or even books dealing with this technology, relatively little is known about the relation between the steel microstructure and the AWJ cutting efficiency. The steel microstructure can be significantly affected by heat treatment. Three different steel grades, carbon steel C45, micro-alloyed steel 37MnSi5 and low-alloy steel 30CrV9, were subjected to four different types of heat treatment: normalization annealing, soft annealing, quenching and quenching followed by tempering. Then, they were cut by an abrasive water jet, while identical cutting parameters were applied. The relations between the mechanical characteristics of heat-treated steels and the surface roughness parameters Ra, Rz and RSm were studied. A comparison of changes in the surface roughness parameters and Young modulus variation led to the conclusion that the modulus was not significantly responsible for the surface roughness. The changes of RSm did not prove any correlation to either the mechanical characteristics or the visible microstructure dimensions. The homogeneity of the steel microstructure appeared to be the most important factor for the cutting quality; the higher the difference in the hardness of the structural components in the inhomogeneous microstructure was, the higher were the roughness values. A more complex measurement and critical evaluation of the declination angle measurement compared to the surface roughness measurement are planned in future research.

scholarly journals Avoiding CFRP Delamination During Abrasive Water Jet Piercing: A New Piercing Method

2021 ◽  
Author(s):  
Ioan Alexandru Popan ◽  
Nicolae Bâlc ◽  
Alina Ioana Popan
Keyword(s):  
Composite Materials ◽  
High Speed ◽  
Water Pressure ◽  
Dimensional Accuracy ◽  
Water Jet ◽  
Abrasive Water Jet ◽  
Environmental Friendliness ◽  
Abrasive Particles ◽  
Awj Cutting ◽  
Cutting System

Abstract Carbon Fibre Reinforced Polymer (CFRP) is used in top industries like aerospace, automotive or medicine. Abrasive water jet (AWJ) technology has demonstrated its capacity in machining CFRP parts with a high dimensional accuracy due to its low mechanical loading, reduced machining temperature, high productivity, reduced tooling, and environmental friendliness. An important challenge when machining composite materials with AWJ is material delamination, determined by the high-speed water jet hitting the material during the piercing process. It is the ideal tool for cutting complex CFRP parts, in cases where the piercing point is outside of the workpiece. The challenge lies in machining features where material piercing is required, like holes, slots or internal contours. This paper presents a method of piercing the composite materials with abrasive water jet, that can avoid delamination. The method requires adding the abrasive particles in the water jet at the very beginning of jet formation, thus obtaining a mixed abrasive water jet during the first impact with the composite workpiece. A new cutting system was designed and set up based on the proposed piercing method and was compared with a conventional AWJ cutting system. The insertion of the abrasive particles into the water jet was monitored by using acoustic emission (AE). An analysis of the influence of piercing parameters (water pressure, standoff distance, abrasive inlet angle and abrasive delay time) on the delamination was conducted. The process outcomes such as hole surface integrity, delamination, particles embedment, uncut fibers and dimensional characteristics, were evaluated. The results show that the method is promising in reducing delamination.

scholarly journals Application of Laser Profilometry to Evaluation of the Surface of the Workpiece Machined by Abrasive Waterjet Technology

2019 ◽  
Vol 9 (10) ◽  
pp. 2134
Author(s):  
Gerhard Mitaľ ◽  
Jozef Dobránsky ◽  
Juraj Ružbarský ◽  
Štefánia Olejárová
Keyword(s):  
Stainless Steel ◽  
Water Jet ◽  
Abrasive Waterjet ◽  
Abrasive Water Jet ◽  
Roughness Parameters ◽  
Roughness Measurement ◽  
Cutting Head ◽  
Water Jet Cutting ◽  
Laser Profilometry ◽  
Laser Profilometer

The paper is an evaluation of the surface roughness of various materials produced by water jet cutting (AWJ, abrasive water jet). A 3D laser profilometer developed at the Department of Design and Technical Systems Monitoring at our University was used in roughness measurement. To verify the values measured by the laser profilometer, another measurement was performed using a 2D contact roughness meter. The tests were done on aluminum and stainless-steel materials, respectively. Six samples were produced; three made of stainless steel and three made of aluminum. All samples were produced at a different feed rate of the cutting head. This was adapted to the different roughness required, per the manufacturer’s material data sheets. Varying rates of separation translated into different qualities of the surfaces under evaluation. The evaluated roughness parameters were Ra and Rz. Dependencies were plotted in the chart based on the values measured, which were then compared and evaluated.

scholarly journals Jet lagging in abrasive water jet cutting of high-speed tool steel

2021 ◽  
Vol 27 (2) ◽  
pp. 73-80
Author(s):  
Ramiz Kurbegovic ◽  
Mileta Janjic
Keyword(s):  
High Speed ◽  
High Speed Steel ◽  
Traverse Speed ◽  
Water Jet ◽  
Abrasive Waterjet ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Abrasive Water Jet ◽  
Working Pressure ◽  
Water Jet Cutting

Abrasive water jet machining is a very efficient unconventional method for contour cutting of different types of materials. As one of the main characteristics of the quality of surfaces machined with this method is curved lines that appear during machining. These lines are a consequence of the deviation of the abrasive water jet from its ideal vertical line, jet lagging, which are the cause of machining errors. The aim of this work is to investigate the influence of machining parameters on jet lagging. The samples of high-speed steel EN HS6-5-2 (JUS c.7680) were machined with an abrasive water jet under varying working pressure, traverse speed, abrasive mass flow rate, and stand-off distance. The jet lagging was measured at twenty places along with the depth of cut, and based on these results, the relationship between the jet lagging and machining parameters has been formed. In order to correctly select the process parameters, an empirical model for the prediction of jet lagging in abrasive waterjet cutting of high-speed steel EN HS6-5-2 was developed using regression analysis. This developed model has been verified with the experimental results that reveal high applicability of the model within the experimental range used.

scholarly journals Process Parameter Optimization for Abrasive Water Jet Machining of Titanium Alloy Using Meta-Heuristic Algorithms

2018 ◽  
Vol 221 ◽  
pp. 01004
Author(s):  
Vishal S Sharma ◽  
Amit Kumar ◽  
Munish Kumar Gupta ◽  
Neeraj Bhanot
Keyword(s):  
Titanium Alloy ◽  
Process Parameters ◽  
Heuristic Algorithms ◽  
Removal Rate ◽  
Short Interval ◽  
Water Jet ◽  
Abrasive Water Jet ◽  
Influence Of Process Parameters ◽  
Abrasive Water Jet Machining ◽  
Industrial Sectors

Recently, the trend of optimization algorithms for improvements of surface quality and productivity characteristics in abrasive water jet machining of titanium alloy (Ti-6Al-4V alloy) has become increasingly more widespread in various industrial sectors i.e., aircraft and automobile Industries. Here, the present research attempts to select the ideal or best AWJM process parameters by implementing the well known meta-heuristic algorithm i.e., Teacher learning based optimization method (TLBO). The AWJM experiments as per the Taguchi L9 orthogonal array were performed on Ti 6Al-4V titanium alloy by considering jet transverse speed, stand-off distance and abrasive flow as the input parameters. Then, the influence of process parameters on surface roughness and material removal rate has been performed by means plot and ANOVA analysis. After that, the results are optimized with the TLBO method. The overall results indicate that the TLBO method is an efficient method used to find the optimal results with very short interval of time i.e., within 3 sec.

The Effect of Water Pressure Variation on Cut Surfaces Quality during Abrasive Waterjet Cutting of Austenitic Steels

2014 ◽  
Vol 1029 ◽  
pp. 176-181 ◽  
Author(s):  
Ion Aurel Perianu ◽  
Ion Mitelea ◽  
Viorel Aurel Şerban
Keyword(s):  
Water Pressure ◽  
Austenitic Stainless Steels ◽  
Water Jet ◽  
Pressure Variation ◽  
Austenitic Steels ◽  
Abrasive Waterjet ◽  
Abrasive Water Jet ◽  
Effect Of Water ◽  
Water Jet Cutting ◽  
Abrasive Water Jet Cutting

In this paper research elements regarding the effect of water pressure variation on cut surfaces quality are presented in the field of abrasive water jet cutting of materials hard to process by machining such as austenitic stainless steels, in this case with a thickness of 20 mm. Selection of the optimal cutting process based on technical and economic criteria takes into consideration the type and thickness of the targeted material and also the physical and geometrical quality requirements. The present paper contains experimental research results regarding abrasive water jet cutting of austenitic stainless steel EN 1.4306 (ASTM 304 L) at different values of water pressure. The abrasive material used is Garnet with particle granulation 80 Mesh. By making roughness measurements and hardness examinations of the cut surface an evaluation will be made of the surface quality defining the optimal pressure values.

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