Abrasive Water Jet Research Articles

Abrasive waterjet machining of titanium alloy using an integrated approach of taguchi-based passing vehicle search algorithm

AbstractThe titanium alloy, Ti6Al4V, is a popularly used material in aerospace and medical applications due to its specific attributes, such as excellent strength-to-weight ratio and resistance to corrosion. Ti6Al4V is challenging to machine using conventional methods due to its poor thermal conductivity, which necessitates the use of unconventional machining methods like abrasive water jet machining (AWJM). In this work, AWJM was preferred for machining Ti6Al4V, considering three key process variables: nozzle traverse speed (Tv), abrasive flow rate (Af), and stand-off distance (Sd). The performance of the AWJM process was assessed using three main metrics: Material removal rate (MRR), Surface roughness (SR), and Kerf taper angle (θ), which were crucial for evaluating the effectiveness of the AWJM. Taguchi’s L9 array, a design of experiments method, was used to plan the experiments. The adequacy of the developed models was assessed by analysis of variance (ANOVA). ANOVA results have shown that Tv, Af, and Sd were found to have a significant effect on MRR, SR, θ with contributions of 73.15%, 49.72%, and 78.35% respectively. The Passing Vehicle Search algorithm was adopted to find the global optimal solution. Simultaneous optimization results using the PVS algorithm have shown the optimal MRR, SR, and θ values of 0.17 g/min, 3.28 μm, and 2.45, respectively, at Tv of 237 mm/min, Af of 450 g/min, and Sd of 2.0 mm. The optimization results with Pareto points will help to achieve desired outcomes by selecting appropriate input conditions.

Improving the Machining Performance of Polymer Hybrid Composite by Abrasive Water Jet Machining for Precise Machining

Improving the Machining Performance of Polymer Hybrid Composite by Abrasive Water Jet Machining for Precise Machining

CFD-Based Study on the Flow and Kinetic Energy Characteristics of a Supercritical Suspended Abrasive Water Jet in the Deep-Sea Environment

A supercritical suspended abrasive water jet with dual inputs of pressure and heat is proposed to improve the cutting performance of the conventional suspended abrasive water jet in deep-sea environments. The paper studies the flow and kinetic characteristics of the supercritical suspended abrasive water jet. The CFD simulation method is proposed to investigate these characteristics by integrating a programmed database of supercritical water material properties with Ansys Fluent. The simulation and comparison show that abrasive particle density, abrasive particle size, inlet pressure, and water temperature affect the acceleration process of the abrasive particles. At the nozzle outlet, the velocity of the abrasive particles reaches over 95% of the supercritical water velocity. With the proposed supercritical abrasive water jet, the jet velocity is increased by 192.2% to 402.40 m/s compared to the conventional suspended abrasive water jet, reducing the amount of water used by 67.7% at a specified temperature of 773.15 K. Correspondingly, the medium kinetic energy is increased by 177.7% and the medium kinetic energy ratio is 2.78. The particle kinetic energy is increased by 723.2% and the particle kinetic energy ratio is 8.23.

Semi-empirical model for abrasive particle velocity prediction in abrasive waterjet based on momentum transfer efficiency

AbstractAbrasive waterjet (AWJ) is a technology that removes a target material with an abrasive accelerated by ultra-high-pressure water. Recently, its application for rock excavations in civil and geotechnical engineering has increased. AWJ excavation performance is affected by the abrasive velocity formed by momentum transfer during mixing and acceleration. The abrasive velocity varies owing to changes in the abrasive flow rate, focusing tube diameter, and focusing tube length. In this study, the momentum transfer efficiency (MTE) according to the abrasive flow rate and focusing tube geometry was investigated by a numerical analysis to better understand the multiphase flow inside the AWJ system. The MTE was defined based on the theoretical relationship between the abrasive velocity ratio and focusing tube factor, and evaluated through the empirical relationship between the water stiffness and focusing tube length. The optimal abrasive flow rate for generating efficient MTE was approximately 15 g/s, which enabled economical and effective acceleration of abrasive particles. Accordingly, a prediction model based on the derived MTE was developed for the final abrasive velocity generated at the tip of the focusing tube. Using the prediction model, it is possible to evaluate the comprehensive relationship between various AWJ parameters. Based on the prediction model, the abrasive–water flow ratio to generate the optimal abrasive velocity was 0.83. The developed prediction model provides guidelines for selecting the optimal focusing tube geometry and applying an economical abrasive flow rate when designing an AWJ system.

Granite cutting performance depending on the traverse speed in abrasive waterjet multi-cutting

Granite cutting performance depending on the traverse speed in abrasive waterjet multi-cutting

Influence of Awj Parameters on Material Removal Rate, Surface Roughness, and Kerf Angle during Machining of Prosopis Juliflora Bark Fibres/Carbon Reinforced Hybrid Polymeric Composites

This study investigates the impact of changing the settings of the Abrasive Water Jet (AWJ) on the material removal rate (MRR), surface roughness, and kerf angle during the machining process of carbon-reinforced hybrid polymeric composites and Prosopis juliflora bark fibres. The hybrid nature of these materials presents unique machining opportunities as well as difficulties. As a result, optimizing the AWJ settings is essential for productive and efficient machining. The findings demonstrate the intricate connections between the AWJ parameters and the machining characteristics of the hybrid composite. To optimize MRR while minimizing surface roughness and controlling the kerf angle, the optimal parameter combinations are identified. The findings provide valuable insights for the manufacturing industry, particularly concerning sustainable materials and hybrid composites.

Analysis and Basics of Improving the Process of Cutting Electrical Sheet Bundles with a High-Pressure Abrasive Water Jet.

Electrical steels are widely used in the electrical industry in the construction of many devices, e.g., power transformer cores and distribution transformers. An important parameter of electrical components that determines the efficiency of devices is energy loss during remagnetization. These losses are influenced, among other factors, by steel cutting processes. The common techniques for cutting electrical materials on industrial lines are mechanical cutting and laser cutting. High-pressure abrasive water jet (AWJ) cutting, unlike the technologies mentioned above, can ensure higher quality of the cut edge and limit the negative impact of the cutting process on the magnetic properties of sheet metal. However, the correct control of the process and the conditions of its implementation comprise a complex issue and require extensive scientific research. This work presents a new approach to cutting electric sheets, involving bundle cutting, which significantly increases the processing efficiency and the dimensional and shape accuracy of the cut details. The tests were carried out for bundles composed of a maximum of 30 sheets, ready to be joined in a stator and rotor in a motor. The influence of processing conditions on the quality of the cut edges of sheet metal, the width of the deformation zone, and the burr height were analyzed. The detailed analysis of the quality of the cut edges of electrical bundled sheets creates new possibilities for controlling the AWJ cutting process in order to obtain a product with the desired functional and operational properties.

The influence of pulse frequency on the energy evolution law and rock-breaking effect of pulsed abrasive water jet

Compared to continuous abrasive jet and high-pressure water jet, pulsed abrasive water jet can intermittently generate high water hammer pressure and is commonly used in applications such as coal mining and petroleum engineering for rock-breaking purposes. Pulse frequency is one of the key factors affecting the evolution of abrasive acceleration and jet impact energy, thereby influencing the system's energy transfer efficiency and cutting ability. The equation of motion for abrasive acceleration is established based on the two-phase flow theory, and the variation law of abrasive velocity with pulse frequency is solved. Fluent-EDEM (Extended Discrete Element Method) was used to simulate the abrasive water jet flow field structure and abrasive acceleration process under different pulse frequency conditions, and the intrinsic influence mechanism of pulse frequency on impact energy was clarified. Combined with rock-breaking experiments using pulsed abrasive water jets, the following conclusions are drawn: as the pulse frequency increases, the inertia of the abrasive makes it unable to respond in a timely manner to the high pulsation frequency of water, resulting in a reduction in the exchange rate of intermittent energy and a gradual decrease in the maximum velocity of the abrasive. This trend is more pronounced at a higher pulse frequency. Within the same time period, the cumulative impact energy of the pulsed abrasive water jet decreases first and then increases with the increase in pulse frequency, indicating the existence of an optimal impact frequency that maximizes the cumulative impact energy of the pulsed abrasive water jet. Under fixed jet pressure conditions and the same erosion time, the pulsed abrasive water jet with a frequency of 30 Hz exhibits the best rock-breaking capability.

Study on fatigue crack growth property of abrasive waterjet peened aluminum alloy

Abrasive waterjet peening is a favorable surface treatment method for improving the fatigue resistance of metal materials. An insight into the fatigue crack growth properties of AWJ peened specimens is meaningful for obtaining better strengthening performance. In present work, a numerical model of AWJ peening was established and experimentally validated for investigating the fatigue crack growth characteristics of Aluminum specimens. The effect of peening and loading conditions on the fatigue performance was also analyzed. The results indicated that the stress intensity factor at the peened region was enhanced and the crack propagation was significantly inhibited by the compressive residual stress. The influence of compressive residual stress on the effective stress factor range is greater under lower external load and higher loading ratio. The fatigue life for reaching the crack length of 40 mm is increased by 37%, 60% and 98% after peening by using the intensity of 0.6 mmA, 0.8 mmA and 1 mmA, respectively.

Parameters Optimization on Abrasive Water Jet Machining of Zerconia Ceramics

Abstract: Ceramic materials play a vital role in industries for several reasons, owing to their unique combination of properties such as high temperature resistance, high wear and abrasion resistance and electrical insulation. Conducting experiments on an abrasive water jet machine involves manipulating three input parameters at three levels each. The parameters are water pressure (1.5 bar, 2.5 bar, and 3.5 bar), standoff distance (4 mm, 8 mm, and 12 mm), and abrasive flow rate (6 gm/sec, 12 gm/sec, and 18 gm/sec). The responses measured are material removal rate (MRR) and surface roughness (Ra). To systematically study the impact of these parameters the Design of Experiments (DOE) methodology is employed utilizing the L9 Orthogonal Array (OA) to streamline the experimental design. The Taguchi technique is then applied to predict the optimal process parameters. For a comprehensive analysis of Variance (ANOVA) is employed to quantify the percentage contribution of each input parameter to the responses shedding light on their relative significance. Additionally the regression coefficient (R2 ) is assessed to gauge the degree of agreement between the experimental and predicted values for the responses

Effect of standoff distance and traverse speed on the cutting quality during the abrasive water jet machining (AWJM) of brass

The research aimed to study the impact of changing the stand-off distance (SOD) and traverse speed (TS) on the results of abrasive water jet (AWJ) machining on brass surfaces. The study specifically evaluated the kerf width (KW), cutting quality (CQ) and surface roughness (Ra). For this purpose, Abrasive Water Jet Machining (AWJM) was used, and adjustments were made to the SOD and TS to obtain the best cutting quality for 0.8-mm-thick brass sheets. The results showed that to achieve high cutting quality, it was necessary to reduce the SOD and increase the TS to minimize the KW. Conversely, higher TS and Ra resulted in decreased cutting quality. The largest KW was recorded at an SOD of 5 mm and TS of 90 mm/min, measuring 6.537 mm. Fine-tuning the SOD by 1 mm at the same TS produced the best machining outcomes, with a minimum KW of 1.706 mm, indicating superior cut quality. Lower cutting quality was observed at higher traverse speeds and surface roughness. The optimal Ra was achieved at 90 mm/min with an SOD of 5 mm, measuring 1.1 µm, while the maximum Ra was observed at 150 mm/min with an SOD of 1 mm, measuring 8.15 µm.

AN IN-DEPTH INVESTIGATION ON KERF ANGLE IN PIERCED HOLE ON INCONEL-625 SUPERALLOY USING ABRASIVE WATERJET CUTTING PROCESS

This work investigates the piercing of microholes in turbine shroud rings (Inconel-625) using the Abrasive Waterjet Cutting process. The concern with the hole piercing is the kerf angle caused by the attenuation of the jet energy and stand-off distance, which seriously impacts the processing precision of abrasive water jet piercing. The effects of piercing parameters like machining time (40, 60 and 80[Formula: see text]s), abrasive mesh size (80 mesh and 120 mesh), stand-off distance (1, 2, 3 and 4[Formula: see text]mm), abrasive jet pressure (100, 125, 150 and 175[Formula: see text]MPa) are studied to reduce the kerf angle. The kerf angle increased linearly with a stand-off distance increase at different machining times. By piercing for 60[Formula: see text]s and 80[Formula: see text]s, the lowest values of kerf angle are obtained (0.03∘ and 0.02∘). The optimum conditions for making a pierced hole with a minimum kerf angle of 0.02∘ were achieved with a machining time- of 60[Formula: see text]s, abrasive mesh size- of 20 mesh, and abrasive jet pressure- of Scanning electron microscope (SEM) images and visual measuring system (VMS) images are used to identify the surface characteristics in kerf zone. The features, including ploughing, particle embedment, lip impression and wear path due to the ductile mode of erosion caused by high energy impact, is also discussed.

Structural optimization design of ice abrasive water jet nozzle based on multi-objective algorithm

To enhance the cleaning efficiency of the ice abrasive water jet (IAWJ), the nozzle in the jet structure was optimized. The cleaning effect of nozzle with different structural design is different. The design variables include the geometric parameters of the nozzle's structure and the flow process parameters of the jet. The maximum wall static pressure, outlet velocity and wash width are the optimization objectives. Based on the Optimal Latin Hypercube Sampling (OLHS) method, 50 sets of sample capacity were designed for simulation calculation. The parameter functions associated with the three objectives were fitted by MATLAB. The Competitive mechanism multi-objective particle swarm optimizer (CMOPSO) algorithm was used to optimize the nozzle to improve the cleaning effect, which was verified with the test results. The inlet pressure and outlet diameter are critical factors influencing the cleaning effect of the IAWJ. The maximum wall static pressure produced by the optimized nozzle is about 4.5% higher than that of the ordinary cosine nozzle. The cleaning effect of the optimized nozzle is 10% higher than that of the ordinary cosine nozzle, which is verified by the experiments. The optimization of the nozzle serves as a valuable reference for the nozzle structure design of the cleaning machine.

Analysis based on surface and kerf performance in multi-simultaneous cutting of S235JR structural steel with abrasive water jet

The use of S235JR structural steel materials is common in the manufacturing industry. These materials are typically supplied as plates and cut to the desired dimensions. However, conventional machining methods used to obtain smaller parts from these plates have quality, cost and time difficulties. Advanced manufacturing methods for mass production can cut materials in bulk, resulting in more parts in a shorter time. This study investigates the effects of an abrasive water jet on stacked plates through multi-simultaneous cutting. The experimental parameter of the gap distance between the stacks was varied to examine its effect on surface roughness and kerf widths. The results were used to explain the cutting mechanisms. Based on an analysis of surface and kerf performance, it was found that an inter-stack distance of 2 mm behaves like a single plate cutting for the stacks. The implemented concept defines inter-stack distance values that contain the optimum cutting performance outputs for multi-simultaneous cutting.

INNOVATIVE MATERIAL PROCESSING TECHNIQUES IN PRECISION MANUFACTURING: A REVIEW

Precision manufacturing plays a pivotal role in various industries, demanding high accuracy, efficiency, and quality in the production process. The continual pursuit of innovation in material processing techniques is essential to meet evolving demands and challenges. This review explores the latest advancements and innovations in material processing methods within precision manufacturing. The review encompasses a comprehensive analysis of various innovative material processing techniques, including additive manufacturing, subtractive manufacturing, and hybrid approaches. Additive manufacturing, often referred to as 3D printing, has gained significant attention for its capability to produce complex geometries with high precision. The exploration of novel materials, such as metal alloys, polymers, and composites, expands the applicability of additive manufacturing in diverse industrial sectors. Subtractive manufacturing techniques, such as milling, turning, and grinding, are also undergoing transformative advancements to enhance precision and efficiency. Emerging technologies like abrasive waterjet machining, electrical discharge machining (EDM), and laser machining offer improved accuracy and surface finish while enabling the processing of a wide range of materials, including hard-to-machine alloys and composites. Hybrid manufacturing approaches, combining additive and subtractive techniques, are revolutionizing precision manufacturing by leveraging the strengths of both methods. These hybrid systems enable the production of intricate components with high precision, reduced lead times, and minimized material waste, addressing the challenges of traditional manufacturing processes. Furthermore, the review highlights advancements in process monitoring and control technologies, such as in-process sensing, real-time feedback systems, and adaptive control algorithms, facilitating enhanced quality assurance and productivity in precision manufacturing. The integration of advanced computational tools, simulation techniques, and artificial intelligence further augments the optimization and customization capabilities of material processing techniques, driving efficiency and innovation in precision manufacturing. Overall, this review provides valuable insights into the latest developments and trends in innovative material processing techniques, offering a roadmap for future research directions and applications in precision manufacturing industries.
 Keywords: Material, Processing, Techniques, Precision, Manufacturing, Review.

Determination and prediction of surface and kerf properties in abrasive water jet machining of Fe-Cr-C based hardfacing wear plates

Improving and maintaining the sustainability, profitability and efficiency of sectors such as manufacturing, mining and agriculture are the most important goals for industries. It is therefore quite common to apply hardfacing method to products and equipment created to achieve these goals. However, machining of the workpiece is necessary to ensure dimensional accuracy as a result of hardfacing production. In the processing of hardfacing materials with traditional machining methods, negative factors such as tool wear and thermal effects occur. For this reason, the cutting performance of hardfacing wear plate with abrasive water jet, which is one of the unconventional manufacturing processes, was investigated in this study. Tests were realized in regard to the full factorial experimental design, which includes the changes in the levels of material alignment direction, abrasive mass flow rate and traverse speed parameters. The influences of the test parameters on the surface roughness and kerf taper angle constituting the cutting performance were determined by analysis of variance (ANOVA). In addition, the effects of changes in parameter levels were investigated. Material alignment direction was found to be the most effective test parameter for surface roughness and kerf taper angle. The influences of parameter and parameter levels on the formation of surface conditions were determined with surface images. Thus, machining mechanisms and surface morphologies were explained by scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). Optimal levels of test parameters were achieved by performing multiple-response optimization with equal importance. Finally, the estimated results of cutting performances were found by general linear model, and all results were confirmed by regression analysis.

Bearing strength performance: A study on the influence of AWJ drilling and delamination of GF/Al‐mesh reinforced polymer composites

AbstractFiber‐reinforced composites acquire widespread use in the technologically advanced sectors on account of their lightweight and outstanding strength. Considering the significant connection between component quality and durability, bearing strength is a critical factor in the mechanically assembled parts during the manufacturing process. Therefore, in this paper, an experimental study was performed on hybrid glass fiber/aluminum‐mesh composites to assess the impact of abrasive water jet (AWJ) drilling on delamination and bearing strength. The samples were drilled, and the delamination damage was assessed. Finally, the bearing test was conducted on the sample in conformity with ASTM D5961M. The impact of stress distribution on the specimen's failure patterns was studied. Experimental outcomes reveal that the GFA specimen had a 2.9% higher average bearing strength than the AGF specimen. The drilling‐induced damage was determined to be the primary factor responsible for a 27% reduction in bearing strength. The optimization of operational parameters yields improved bearing load and lower damage. A significant level of conformity was detected by the regression accuracy and validation test results with a residual error of less than 10%.Highlights A comparison of two hybrid composites utilizing various layouts for damage and load bearing. Delamination damage is a key factor in predicting the efficiency of bolted connections. Using optimized operation parameters enhances drilling output response significantly.

Two-way coupled CFD-DEM model of a pre-mixed abrasive water jet and its application to the investigation of abrasive motion characteristics

This paper uses the weight function to modify the particle volume fraction algorithm. The VOF model is modified by adding the particle phase volume fraction and momentum source to the control equation, the semi-resolved VOF-DEM model is established, and PTV experiment is used to verify the model. Based on this model, the flow and distribution characteristics of the abrasive are obtained: 1) The water-abrasive flow near the outlet of the convergent section of the nozzle has a significantly dense two-phase flow characteristic, and the collision between particles dominates particle flow. 2) The particles at the nozzle outlet are distributed in the radial direction of “n”, and with the increase of the stand-off distance of the jet, the particle phase volume transitions from “n” to “m” distribution. The research on the flow characteristics of particles can provide a basis for the nozzle design of pre-mixed abrasive water jets.

An experimental investigation into the influence of water column height in submerged mode of abrasive waterjet trepanning on the hole quality

Abrasive waterjet (AWJ) trepanning/drilling exhibits immense potential to realize holes of various shapes and sizes in a diverse range of materials, ranging from soft-and-ductile to hard-and-brittle, making it highly valuable for various industries. AWJ trepanning offers the advantage of not requiring tool changes to accommodate different hole shapes and sizes; adjusting the jet path can produce the desired hole geometry, proving exceptionally advantageous for mass production. However, the stochastic nature of the jet results in geometrical errors (diametric deviation, taper angle (α)), form errors (circularity error (Ce), cylindricity error (Cy)) and quality issues (damage region, edge radius (R), surface roughness (Ra), and waviness (Wa)). To address these issues, trepanning in submerged mode can be adopted as it attenuates the mist region and aggressiveness of the jet. This study analyzes the influence of the submerged mode of trepanning on the geometry, form, and quality of trepanned holes relative to the in-air mode. The study found that submerged trepanning produces a more consistent hole diametrical profile along the depth and minimizes the average Ce and α by 23.18 % and 29.20 %, respectively. The maximum Cy in in-air trepanning was reduced in submerged mode by 36.76 %. The average damage region and R reduced by 50.80 % and 35.49 %, respectively. The qualitative and quantitative analysis of the trepanned surface morphology is presented in-air and submerged mode: the results show that the Ra and Wa decrease at the hole entry and middle zone and increase at the exit zone. Finally, the process parameters level settings for achieving near-optimal trepanning responses (α, Cy, Ce, damage region, R, Ra, and Wa) suggested with the help of mean response- and parallel coordinate- plots. Micrographs of submerged trepanned surfaces show that the material removal mechanism (MRM) governs by shallower craters and grooves at the entry and middle zone of the hole, and at the exit zone, the MRM is random, in comparison to the in-air mode.

Research on the Features of Synchronous Cutting of Granite by Abrasive Water Jet and Disc Cutter

Research on the Features of Synchronous Cutting of Granite by Abrasive Water Jet and Disc Cutter