Modelling of high velocity, loose abrasive machining processes

doi:10.1016/S0007-8506(07)61513-3

CIRP Annals

Volume 51, Issue 1, 2002, Pages 263-266

https://doi.org/10.1016/S0007-8506(07)61513-3 Get rights and content

Abstract

In the recent years the interest in loose abrasive machining processes as efficient, flexible processes is rising. This paper describes the development of a ‘coherent set of models’ for a category of these processes, namely those which use high velocity of the particles to obtain the necessary energy to machine a workpiece surface. The usability of this ‘coherent set of models’ will be explained with its application in the field of high-pressure abrasive waterjet cutting. At the end of this paper a forecast to the application of this modelling technique to other loose abrasive machining processes as Micro-Abrasive Air Jet Machining is given.

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Opportunities in Abrasive Water-Jet Machining
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A.M. Hoogstrate
Towards High-Definition Abrasive Waterjet Cutting
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There are more references available in the full text version of this article.

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This method can be expensive in terms of equipment and time-consuming [16]. In this current work, a method for measuring particle velocity was adopted from systems used to measure abrasive particle velocity in erosion testing [17–20]. Details of the setup can be found in Section 2.3.
Four powders with varying bulk densities, Al, Al₂O₃, Sn, and Cu, were used to determine quantifiable relationships between powder flowability, mass flow rate, and powder velocity with particle morphology and particle distribution in a cold spray system. High particle density results in good powder flowability, specifically when the powders are spherical relative to irregular morphology. Particle velocity during cold spray, measured with a double disk rotary system, increases non-linearly with an increase of inlet pressure. The increase in mass flow rate from the hopper and the resulting mass output of the cold spray system shows a consequence of good powder flowability. Conversely, a high mass flow rate decreases the particle velocity during the cold spray process, with better flowability leading to decreases on the order of 10% in particle velocity in the cold spray system. The described methods, proposed tools, and findings can be easily made with cost-effective and on-the-spot measurements.
Modeling of abrasive waterjet generated kerf on the top layer of a multi-layered structure
2022, CIRP Journal of Manufacturing Science and Technology
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Bitter's erosion theory is used to determine the volume of material eroded from which the AWJ drilled hole's kerf profile using the jet profile obtained by balancing the momentum between the incoming jet and the outgoing jet's drag forces [19]. Further, an attempt was made to apply the concepts of generalized kerf shape and specific cutting energies as heat energy required for melting the materials to predict the depth of kerf (h) [20,21]. On the other hand, a single parameter “AWJ machining erosion resistance” is defined for ceramic materials, based on which a simplified erosion model was developed for determining the volume removed from a single impact [22].
Abrasive waterjet (AWJ) is an effective tool for manufacturing parts from multi-layered structures (MLSs) due to its capability in machining a wide range of materials. However, the challenge in employing AWJ in producing the desired kerf geometry in MLS can be attributed to the complex nature of the jet's interaction with multiple layers that possess different material properties. Hence, a model that captures the interaction of the jet with MLS, and predicts the whole kerf geometry is required to gain control over the kerf quality. On the other hand, the kerf generated in a layer is affected by the presence of preceding-/following- layers. In this context, it is essential to develop a comprehensive model for the prediction of kerf profile during the penetration of the jet in each layer. Although, several models exist to predict the process response (erosion depth, top (w_t), and bottom kerf width (w_b), kerf taper), very limited models available on kerf profile prediction. Further, neglecting the actual jet characteristics limits their ability to predict accurately. By considering the above, this work proposes a model for the prediction of the kerf geometry (profile and characteristics) in a single layer of MLS along with its kerf characteristics apart from considering the non-linearities, such as jet characteristics and the effects of AWJ process parameters. A discretized form of the jet, abrasives mass flow distribution, and their velocity in the jet plume to realize a more realistic model for predicting kerf geometry. Further, a new parameter, 'depth of damaged region’ was defined towards realizing the w_t. The model was evaluated by comparing the kerf geometry formed on mild steel (MS) and aluminum (Al) materials by using root mean square and mean absolute error. The proposed model was found to predict the kerf geometry accurately.
A study on abrasive waterjet multi-stage machining of ceramics
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Abrasive waterjet (AWJ) milling is a promising technique for machining hard materials, but it is also complex to implement. In modern production scenarios, multi-stage machining is a matter of course to improve both performance and quality. Since AWJ milling is still developing, there is little knowledge about a corresponding process design.
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Microabrasive technology for precision cleaning and processing applications
2018, Developments in Surface Contamination and Cleaning: Applications of Cleaning Techniques Volume 11
Microabrasive technology is a highly versatile, nonsolvent, automated precision cleaning and processing system that has been developed to meet the growing demand for precision cleaning and processing needs in the government and industrial sectors with generation of minimum quantities of nonhazardous secondary waste. The system employs miniature nozzles through which a dry microabrasive powder is propelled onto the surface of the part to be cleaned or processed. The system can be used in a variety of applications, including coating removal, component demarking, deburring, drilling and cutting, surface texturing and etching. The versatility of the technology is illustrated by specific examples of its use in a variety of industries.
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Microabrasive processing is a versatile, dry cleaning, and processing technique. The process uses a miniature nozzle through which a precisely graded abrasive powder, mixed with compresses air or other inert gas, is directed onto the surface of the part to be cleaned. The process is controlled by five key parameters, such as air or other gas pressure, powder flow rate, and dwell time. Microabrasive technology has been developed to a very high degree of sophistication for a wide range of precision cleaning and processing applications, including coating removal, precision deburring, component demarking, drilling and cutting, surface texturing, and etching of a wide range of materials. The work necessary to remove a film is supplied by the kinetic energy of the particle as it impacts the surface. Dynamic effects, such as wave reflection, are negligible and the impact can be treated as quasi-static. Coatings with high interfacial strength are removed by mechanical erosion, while low interfacial strength results in coating removal by delamination. A wide variety of abrasive powders and nozzles are available for diverse applications described in this discussion.
Abrasive fine-finishing technology
2016, CIRP Annals - Manufacturing Technology
Citation Excerpt :
There have been 54 relevant papers published from 1960 to 2015 by the Scientific Technical Committee-Abrasive Process (STC-G) in the Annals of CIRP Vol. 1. The breakdown by the finishing method is: 25 papers on lapping/polishing [12,13,20,25,42,43,45,71,77,78,82,89,92,95,109,125,144–146,149,175,185,191,199,220], 8 in honing [24,41,61,111,128,148,183,204], 8 on magnetic abrasive finishing (MAF) [52,85,163,173,187,210,211,215], 4 on coated abrasives [16,97,158,176], 3 on jet finishing [14,76,87], 3 on superfinishing [28,133,195], and 3 on mass finishing [65–67]. In addition to those, there have been three CIRP keynote papers regarding polishing technology, which have provided invaluable technological overviews.
Abrasive fine-finishing technology is often applied as a final finishing process, and the selection of the right technology is crucial to obtaining the desired performance of functions such as fatigue life. This paper begins with classifications of the technology along with fundamentals and brief histories of the individual methods. The material removal mechanisms, specific energies, and finishing characteristics of the various technologies are summarized giving assessments of the surfaces created by them. Guidelines developed for selecting the appropriate methods, and case studies illustrate the effectiveness of various methods. This paper ends with a discussion of the future prospects of the technology.

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Modelling of high velocity, loose abrasive machining processes

Abstract

Annals of the CIRP

Opportunities in Abrasive Water-Jet Machining

Annals of the CIRP

Towards High-Definition Abrasive Waterjet Cutting