Computational Fluid Dynamics Analysis of Erosion in Active Components of Abrasive Water Jet Machine

Abstract

This study presents a comprehensive three-dimensional computational fluid dynamics (CFD) analysis of abrasive fluid flow and its erosive effects on the active components of the WUXI YCWJ-380-1520 water jet cutting machine. The research investigates the behavior and impact of abrasive particles within the fluid, determining the erosion rates for particles with diameters of 0.19 mm, 0.285 mm, and 0.38 mm (dimensions resulting from the granulometry of the experimentally established sand), considering various abrasive flow rates. The methodology includes a detailed granulometric analysis of the abrasive material, identifying critical particle sizes and distributions, with a focus on M50 granulation (average particle size of 0.285 mm). Additionally, the study employs the Wadell method to determine the shape factor (Ψi = 0.622) of the abrasive particles, which plays a significant role in the erosion process. Experimental determination of the abrasive flow rate is conducted, leading to the development of a second-order parabolic model that accurately predicts flow variations based on the control settings of the AWJ machine. The maximum erosion occurs at the entry surface of the mixing tube’s truncated zone, with a higher intensity as the particle size increases. For the 0.19 mm particles, the erosion rates range from 1.090 × 10−6 kg/m2·s to 2.022 × 10−6 kg/m2·s and follow a parabolic distribution. The particles of 0.285 mm show erosion rates ranging from 2.450 × 10−6 kg/m2·s to 6.119 × 10−6 kg/m2·s, also fitting the second-order parabolic model. The largest particles (0.38 mm) exhibit erosion rates ranging from 3.646 × 10−6 kg/m2·s to 7.123 × 10−6 kg/m2·s, described by a third-order polynomial. The study concludes that larger particle sizes result in higher erosion rates due to their increased mass and kinetic energy. Therefore, the present investigation demonstrates a significant relationship between particle size, abrasive flow rate, and erosion rate, highlighting critical wear points in the machine’s components. The findings contribute to optimizing the design and operational parameters of water jet cutting machines, thereby enhancing their efficiency and lifespan.