高压水射流的CFD仿真及分析

利用计算流体动力学(CFD)的方法对高压水射流进行了多相流的数值模拟,侧重研究在稳态湍流下的两相流和三相流条件下的水射流的动态特性,比较分析了淹没射流与非淹没射流下磨料水射流与纯水射流的区别,并对可视化的图形图像和计算结果进行了分析研究,结果表明,非淹没条件下磨料水射流是高压水切割工具的有效形式。     

提高磨料水射流磨料混合效果的探讨

磨料水射流的性能主要取决于磨料颗粒的冲击速度。本文分析了后混合磨料水射液中磨料颗粒与水混合效果差、磨料颗粒速度低的原因，提出了四种新的混合方式，并从机理上进行了阐述。     

超声辅助微细磨料水射流加工装置的研制及实验研究

为了提高磨料水射流的加工性能,设计了超声辅助微细磨料水射流加工系统,磨料供给采用前混合方式。超声喷嘴装置是该系统的关键,并研究了其加工机理,利用超声振动产生具有空化效应的脉冲水射流,通过脉冲射流的高强度动压力作用和空化作用以提高磨料水射流的加工能力。变幅杆是超声装置的核心部件,通过有限元分析验证变幅杆的性能,确保变幅杆能够有效且准确地工作。冲蚀实验证明:超声振动作用可以提高冲击力及材料去除率。然而,随着振幅的增加,表面质量下降。     

A study on surface roughness in abrasive waterjet machining process using artificial neural networks and regression analysis method

In the present study, artificial neural network (ANN) and regression model were developed to predict surface roughness in abrasive waterjet machining (AWJ) process. In the development of predictive models, machining parameters of traverse speed, waterjet pressure, standoff distance, abrasive grit size and abrasive flow rate were considered as model variables. For this purpose, Taguchi's design of experiments was carried out in order to collect surface roughness values. A feed forward neural network based on back propagation was made up of 13 input neurons, 22 hidden neurons and one output neuron. The 13 sets of data were randomly selected from orthogonal array for training and residuals were used to check the performance. Analysis of variance (ANOVA) and F-test were used to check the validity of regression model and to determine the significant parameter affecting the surface roughness. The statistical analysis showed that the waterjet pressure was an utmost parameter on surface roughness. The microstructures of machined surfaces were also studied by scanning electron microscopy (SEM). The SEM investigations revealed that AWJ machining produced three distinct zones along the cut surface of AA 7075 aluminium alloy and surface striations and waviness were increased significantly with jet pressure.     

THE EROSIVE PROCESS IN ABRASIVE WATERJET CUTTING OF POLYMER MATRIX COMPOSITES

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Modeling of the influence of the abrasive waterjet cutting parameters on the depth of cut based on fuzzy rules

Currently, the abrasive waterjet cutting parameters for the milling operation have to be determined by a combination of prior experience and trial and error. It is shown that the selection of the abrasive waterjet cutting parameters for a required depth of cut in the given material can be effectively done by applying the principles of the fuzzy set theory. This approach will eliminate the need for extensive experimental work in order to select the magnitudes of the most influential abrasive waterjet parameters on the depth of cut. Fuzzy logic provides a methodology and imitation of a human's way of making decisions which is very useful in such applications where the mathematical model of the process does not exist, and one of such processes is indeed abrasive waterjet cutting. A number of case studies are performed to verify the validity of the proposed methodology for selecting the abrasive waterjet cutting parameters in order to achieve the predetermined depth of cut.     

Modeling of waterjet guided laser grooving of silicon

Waterjet guided laser processing is an internationally patented technique based on guiding a laser inside a thin, high-speed waterjet. The process combines the advantages of laser processing with those of waterjet cutting and offers promise as a method for processing thin and heat sensitive materials with a high degree of precision. An improved understanding of the complex interaction between laser, waterjet, and workpiece is required to enable the process to achieve its potential. A model for waterjet guided laser grooving of silicon is presented that treats the energy input of the laser, the cooling effect of the waterjet, and the melting and removal of the silicon. The thermal process is represented in detail in the new method. The model is validated by comparisons of simulation and experimental results, and the simulation provides insight regarding the details of the interactions among laser, waterjet, and workpiece.     

Experimental analysis of irregularities of metallic surfaces generated by abrasive waterjet

Experimental study of the surface quality produced by abrasive waterjet (AWJ) on metallic materials has been performed. The surface roughness/waviness was quantitatively evaluated by using the contactless optical measurement. In order to characterize the cut surface qualities, a single-parameter criterion has been proposed. Based on root mean square (RMS) roughness evaluation of the worst cut surface zone, the dimensionless statistical parameter C can be calculated as a basic quantity for AWJ surface cut characterization. As it was approved, besides its dependency on depth of AWJ trace, the value of C-parameter for the specific material is noticeably related also to the traverse speed of the cutting head. Such a relationship can be potentially used for adjusting the cutting speed of the machining process.     

A strategy for efficient and quality cutting of materials with abrasive waterjets considering the variation in orifice and focusing nozzle diameter

In Abrasive Waterjet (AWJ) cutting, orifice and focusing nozzle diameter undergo continuous change in their dimensions due to erosive nature of high velocity abrasive waterjet. This particular phenomenon can affect the efficiency and quality of the process. To achieve maximum efficiency and desired quality with this process, the parameters need to be optimally selected from time to time considering the changes in the dimensions of orifice and focusing nozzle. In an effort to develop strategies for this purpose and to build the knowledge base for adaptive control of the process, the present work aims to study the influence of orifice and focusing nozzle diameter variation on the performance of abrasive waterjets in cutting 6063-T6 aluminum alloy. The performance was assessed in terms of different parameters such as depth of cut, material removal rate, cutting efficiency, kerf geometry and cut surface topography. In order to maintain the desired performance, it is essential to monitor the condition of nozzles and suitably adjust the process parameters with a view to control the process. Towards the latter, the present work attempts to suggest a strategy that can aid in replacing the nozzles at an appropriate time for maintaining the performance of process within certain limits so as to maintain the precision in machining with abrasive waterjets.     

The effect of cutting head vibrations on the surfaces generated by waterjet cutting

After a first period in which the research has been focused on the optimisation of the process parameters, the attention is now focused on aspects that were usually neglected. However, they are very important in order to understand the physics of the waterjet/abrasive waterjet cutting process and to improve the cutting quality.Particularly, it has been demonstrated that, in the pure waterjet cutting (and in the abrasive waterjet cutting too), there are irregularities, called striations, along the generated surface. The striation formation depends mainly on the jet instability caused by vibrations during the cutting process. Vibration signals have been measured whilst varying the cutting conditions. A model has been studied which estimates the mean spacing and the frequency of the striations, as a function of the period and the amplitude of the jet vibration. This model has been completely validated through measurements of plasticine surfaces generated by waterjet cutting.     

High Performance Cutting with Abrasive Waterjets beyond 400 MPa

Abrasive waterjet (AWJ) cutting has been widely accepted by the industry after the successful introduction of 400 MPa cutting systems. This paper describes the cutting with AWJ beyond the current industrial pressure limit. Firstly, the factors that limit the water pressure are discussed. Secondly, the jet formation is considered by addressing the effects of the geometry of the upstream tube and the orifice. Finally, the AWJ cutting process is described in terms of energy transfer efficiency. There is an optimum abrasive load ratio over which the cutting ability of the jet decreases due to the less efficient power transfer from waterjet to the abrasives.     

Monitoring the depth of abrasive waterjet penetration

In order to control the uniformity of the abrasive waterjet penetration into the workpiece, it is necessary to devise a monitoring methodology that can indirectly monitor the depth of abrasive waterjet penetration. It was shown that the workpiece normal force generated by an abrasive waterjet could be used as the indicator of the depth of jet penetration, and that a force-feedback control holds promise as an effective way to regulate the depth of jet penetration. The effects of different abrasive waterjet process variables on both the depth of cut and the workpiece normal force are discussed.     

On-line monitoring of depth of cut in AWJ cutting

Monitoring of the abrasive waterjet (AWJ) cutting process has become increasingly important. The present paper proposes a model for on-line depth of cut monitoring based on the acoustic emission (AE) response to the variation in AWJ depth of cut, instead of the expensive and impractical vertical cutting force monitoring. The main objective is to use the AE technique in order to predict the actual depth of cut in AWJ cutting under normal cutting conditions. It was found that the root mean square of the acoustic emission energy (AErms) increases linearly with an increase in the depth of cut and could be used for its on-line monitoring. The results show that the AE is the most suitable technique for AWJ monitoring, as the AE signal has high sensitivity to the variation in the depth of cut.     

Stochastic modelling of abrasive waterjet footprints using finite element analysis

The proposal of erosion models to predict the jet footprint during abrasive waterjet machining is a key element for the development of this technology, but it is very challenging because of the inherent fluctuations of the process. This issue becomes critical when the size of the cutting systems is reduced, since the relative size of these deviations increases. The present paper considers for the first time a modelling framework capable of predicting the average shape of AWJM footprints and, of great novelty, the variability along the trench, combining finite element analysis and Monte Carlo methods, and verifying the model using different feed speeds and tilt angles. For that purpose, the relevance of each random parameter, such as shape (sharpness), size and relative orientation of the abrasive particles, has been investigated through parametric studies on these variables. Multiple particle simulations with randomly generated input were performed to determine the effect of operating parameters in the overall variability of the jet footprint. The process was simulated using Abaqus 6.14 as multiple garnet particles hitting a target of Ti–6Al–4V at very high velocity, eroding the target by plastic deformation and material removal. The model shows successfully the influence of single particle parameters, such as the shape, on the surface variability. The results for the footprint variability show that stochastic methods are suitable to model these fluctuations, and it is also shown that this approach yields accurate estimates of the average profile after multiple jet passes with error less than 5%.     

超声辅助磨料水射流加工机制及去除模型研究

为了增强磨料水射流的加工效果,设计了超声辅助微细磨料水射流加工系统。通过喷嘴内变幅杆的超声振动,将声能与射流压力能叠加,增强磨料水射流的脉动行为,形成脉冲射流。通过数值计算的方法研究了流场轴线上的声压分布及磨粒在流场中的运动特性,探究了脉冲射流的加工机制及硬脆材料去除机制。通过切槽实验分析了系统压力、振幅及靶距对冲蚀深度的影响规律,实验结果证明,施加超声振动可有效降低系统压力,最佳靶距为8～10 mm。基于实验结果,利用MATLAB建立了硬脆材料的去除深度预测模型。     

A two-fluid model of abrasive waterjet

Waterjet flow added with abrasive solid particles, the so called abrasive waterjet, can enhance its performance for cutting various materials from soft food products to very hard titanium alloys. In this study, a theoretical analysis is conducted in order to develop a flow model for the abrasive waterjet. The main concern is whether the abrasive particles can be treated as a pseudo-fluid phase. A two-fluid model is developed based on the fundamental laws of conservation. A control volume method is used to discretize the equations, and a phase-coupled SIMPLE algorithm is adopted to solve the pressure–velocity coupling equations. The quasi two-dimensional flow field outside a conventional nozzle used in abrasive waterjet is analyzed and computed to validate the model. Good agreement is observed comparing the numerical results with the experimental measurements.     

高压水冲击强化技术的研究现状及发展

系统介绍了包括磨料高压连续水射流强化、高压脉冲水射流强化和高压空化水射流强化等高压水冲击强化技术的基本原理、强化机理、强化方法及对材料组织性能的影响,总结了国内外在此领域的最新研究进展和发展趋势,并对高压水冲击强化技术的未来发展与应用进行了展望。     

The linear inverse problem in energy beam processing with an application to abrasive waterjet machining

The linear inverse problem for energy beam processing, in which a desired etched profile is known and a trajectory of the beam that will create it must be found, is studied in this paper. As an example, abrasive waterjet machining (AWJM) is considered here supported by extensive experimental investigations. The behaviour of this process can be described using a linear model when the angle between the jet and the surface is approximately constant during the process, as occurs for shallow etched profiles. The inverse problem is usually solved by simply controlling dwell time in proportion to the required depth of milling, without considering whether the target surface can actually be etched. To address this, a Fourier analysis Is used to show that high frequency components in the target surface cannot be etched due to the geometry of the jet and the dynamics of the machine. In this paper, this frequency domain analysis is used to improve the choice of the target profile in such a way that it can be etched. The dynamics of the machine also have a large influence on the actual movement of the jet. It is very difficult to describe this effect because the controller of the machine is usually unknown. A simple approximation is used for the choice of the slope of a step profile. The tracking error between the desired trajectory and the real one is reduced and the etched profile is improved. Several experimental tests are presented to show the usefulness of this approach. Finally, the limitations of the linear model are studied.     

Abrasive waterjet cutting of a titanium alloy: The influence of abrasive morphology and mechanical properties on workpiece grit embedment and cut quality

Abrasive waterjet cutting of material involves the impingement of a high velocity jet of water with entrained abrasive particles (commonly 80 mesh garnet) onto the material to be cut. Embedment of abrasive is known to occur both on the cut-face and on the surface perpendicular to the cut-face where (due to jet divergence) the jet has impinged but not cut through; this grit embedment is a known disadvantage of the process. In this paper, the cut quality and abrasive embedment following waterjet cutting of a commonly used titanium alloy, Ti6Al4V with 80 mesh garnet from five different sources (differing significantly in their hardness, crushing strength and morphology) were examined and evaluated. The cut-face itself was examined to establish the presence or absence of sub-surface embedded abrasive; in addition, the top surface of the plate close to the cut where particles outside the main core of the jet may have impinged was also examined. Embedment levels, surface waviness and roughness and the mechanisms of abrasive–surface interactions were evaluated through a combination of scanning electron microscopy (SEM), energy dispersive X-ray analysis (EDX) and profilometry. It was found that despite the differences in abrasive characteristics, no significant differences in cut quality or abrasive embedment was seen. It was shown that the forces on individual particles during impact can be estimated to be orders of magnitude greater than their crushing load. As such, it is proposed that the majority of abrasive particles will fracture in abrasive waterjetting, and thus any differences in the original abrasive particle morphologies do not dominate behaviour since it is the morphology of the fragments of these fractured particles which control embedment and cut quality.     

Challenges in using waterjet machining of NiTi shape memory alloys: An analysis of controlled-depth milling

The nickel-titanium shape memory alloys (NiTi SMAs) have a very high potential for a wide variety of applications thanks to their unique mechanical properties: shape memory effect and pseudoelasticity. However, they have been proved to be more challenging to cut than other advanced engineering materials because of their high ductility, crystal-oriented and stress-oriented mechanical properties. In stark contrast to the extensive work on the metallurgical/microstructural properties of the SMA, there is limited research regarding non-conventional machining of this group of special alloys.Waterjet technology is well-known for cutting advanced difficult-to-cut materials owing to its benefits of reduced mechanical and thermal damages to workpiece surfaces. This paper reports for the first time the use of waterjet technology to mill the functional shape memory alloys and thus to open new avenues for the utilisation of these alloys for advanced engineering applications (e.g. aerospace, medical fields). However, when it comes to NiTi SMAs (characterised by low temperature phase martensite and parent phase austenite), the insignificant waterjet temperatures become critical to the material behaviour as their crystal structures are sensitive to the variations in both temperature and mechanical compression. This makes the processing (particularly waterjet controlled-depth milling) a real challenging task.By taking into consideration both of the waterjet temperatures at different material removal conditions (i.e. with and without abrasives in the focussing tube) and the transformation temperatures of NiTi, three different working zones (100% martensite; mix of austenite and martensite; 100% austenite) under waterjet process have been proposed. In addition, a combined phase and stress-strain diagram for shape memory effect in martensitic phase and pseudoelasticity in austenite phase of NiTi has been suggested. In this paper, Ni_49.8Ti_50.2 shape memory alloy was considered in which its transition temperature range is overlapped with the waterjet operating temperature; two approaches of waterjet processes (plain and abrasive waterjet milling) were proposed so as to investigate the mechanical and metallurgical effect provoked by the relationship between operating temperatures and transformation temperatures. It was found that abrasive waterjetting is more viable than plain waterjetting for controlled-depth milling of NiTi shape memory alloys.