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20 pages, 7103 KiB

Open AccessArticle

Study of Abrasive Water Jet Machining as a Texturing Operation for Thin Aluminium Alloy UNS A92024

by Fermin Bañon, Alejandro Sambruno, Pedro F. Mayuet and Álvaro Gómez-Parra

Materials 2023, 16(10), 3843; https://doi.org/10.3390/ma16103843 - 19 May 2023

Cited by 3 | Viewed by 1774

Abstract

Surface modification of metallic alloys can create hydrophilic or hydrophobic surfaces that enhance the functional performance of the material. For example, hydrophilic surfaces have improved wettability, which improves mechanical anchorage in adhesive bonding operations. This wettability is directly related to the type of [...] Read more.

Surface modification of metallic alloys can create hydrophilic or hydrophobic surfaces that enhance the functional performance of the material. For example, hydrophilic surfaces have improved wettability, which improves mechanical anchorage in adhesive bonding operations. This wettability is directly related to the type of texture created on the surface and the roughness obtained after the surface modification process. This paper presents the use of abrasive water jetting as an optimal technology for the surface modification of metal alloys. A correct combination of high traverse speeds at low hydraulic pressures minimises the power of the water jet and allows for the removal of small layers of material. The erosive nature of the material removal mechanism creates a high surface roughness, which increases its surface activation. In this way, the influence of texturing with and without abrasive has been evaluated, reaching combinations where the absence of abrasive particles can produce surfaces of interest. In the results obtained, the influence of the most relevant texturing parameters between hydraulic pressure, traverse speed, abrasive flow and spacing has been determined. This has allowed a relationship to be established between these variables and surface quality in terms of Sa, Sz and Sk, as well as wettability. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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19 pages, 4589 KiB

Open AccessArticle

Analysis of Several Physical Phenomena Measured on the Metallic Materials Cut by Abrasive Water Jets (AWJ)

by Jakub Gřunděl, Libor M. Hlaváč, Petr Pětroš and Lucie Gembalová

Materials 2022, 15(21), 7423; https://doi.org/10.3390/ma15217423 - 22 Oct 2022

Cited by 1 | Viewed by 1591

Abstract

Cutting using an abrasive water jet is a complex process involving several physical phenomena. This research studies some of them, mostly the influence of selected variables on the measured forces and vibrations. The traverse speed represents one of the key parameters when cutting [...] Read more.

Cutting using an abrasive water jet is a complex process involving several physical phenomena. This research studies some of them, mostly the influence of selected variables on the measured forces and vibrations. The traverse speed represents one of the key parameters when cutting using the AWJ. In the presented research, a set of experiments was performed on twelve different metal samples, while the force sensor measured the exerted forces and accelerometers measured the vibrations. Ten different types of steel samples of the same dimensions were cut applying five different traverse speeds. The data obtained during these measurements show that an increase in the traverse speed leads to an increase in the measured forces and vibrations. An analogous experiment performed on bronze and duralumin samples of the same dimensions, having applied higher speeds to compensate for the difference in the material structure and properties, completes the presented data. The most important results of the research are that exerted forces in the z-axis are higher than those in the x-axis, whereas measured vibrations are higher in the x-axis. According to our research, the elemental structure, especially the carbide formation, affects the measured forces and vibrations substantially. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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20 pages, 6123 KiB

Open AccessArticle

Intelligent Modeling and Multi-Response Optimization of AWJC on Fiber Intermetallic Laminates through a Hybrid ANFIS-Salp Swarm Algorithm

by Mahalingam Siva Kumar, Devaraj Rajamani, Ahmed M. El-Sherbeeny, Esakki Balasubramanian, Krishnasamy Karthik, Hussein Mohamed Abdelmoneam Hussein and Antonello Astarita

Materials 2022, 15(20), 7216; https://doi.org/10.3390/ma15207216 - 16 Oct 2022

Cited by 10 | Viewed by 1631

Abstract

The attainment of intricate part profiles for composite laminates for end-use applications is one of the tedious tasks carried out through conventional machining processes. Therefore, the present work emphasized hybrid intelligent modeling and multi-response optimization of abrasive waterjet cutting (AWJC) of a novel [...] Read more.

The attainment of intricate part profiles for composite laminates for end-use applications is one of the tedious tasks carried out through conventional machining processes. Therefore, the present work emphasized hybrid intelligent modeling and multi-response optimization of abrasive waterjet cutting (AWJC) of a novel fiber intermetallic laminate (FIL) fabricated through carbon/aramid fiber, reinforced with varying wt% of reduced graphene oxide (r-GO) filled epoxy resin and Nitinol shape memory alloy as the skin material. The AWJC experiments were performed by varying the wt% of r-GO (0, 1, and 2%), traverse speed (400, 500, and 600 mm/min), waterjet pressure (200, 250, and 300 MPa), and stand-off distance (2, 3, and 4 mm) as the input parameters, whereas kerf taper (Kt) and surface roughness (Ra) were considered as the quality responses. A hybrid approach of a parametric optimized adaptive neuro-fuzzy inference system (ANFIS) was adopted through three different metaheuristic algorithms such as particle swarm optimization, moth flame optimization, and dragonfly optimization. The prediction efficiency of the ANFIS network has been found to be significantly improved through the moth flame optimization algorithms in terms of minimized prediction errors, such as mean absolute percentage error and root mean square error. Further, multi-response optimization has been performed for optimized ANFIS response models through the salp swarm optimization (SSO) algorithm to identify the optimal AWJC parameters. The optimal set of parameters, such as 1.004 wt% of r-GO, 600 mm/min of traverse speed, 214 MPa of waterjet pressure, and 4 mm of stand-off distance, were obtained for improved quality characteristics. Moreover, the confirmation experiment results show that an average prediction error of 3.38% for Kt and 3.77% for Ra, respectively, were obtained for SSO, which demonstrates the prediction capability of the proposed optimization algorithm. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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11 pages, 4114 KiB

Open AccessArticle

Temperature Measurement during Abrasive Water Jet Machining (AWJM)

by Damian Bańkowski, Piotr Młynarczyk and Irena M. Hlaváčová

Materials 2022, 15(20), 7082; https://doi.org/10.3390/ma15207082 - 12 Oct 2022

Cited by 4 | Viewed by 4817

Abstract

This study was undertaken to look for confirmation that heat transfer induced by abrasive water jet machining (AWJM) affects the microstructure of the material cut. The structure of S235JR carbon steel used in the experiments was reported to change locally in the jet [...] Read more.

This study was undertaken to look for confirmation that heat transfer induced by abrasive water jet machining (AWJM) affects the microstructure of the material cut. The structure of S235JR carbon steel used in the experiments was reported to change locally in the jet impact zone due to the high concentration of energy generated during cutting with the abrasive water jet. It is assumed that some of the energy is transferred into the material in the form of heat. This is particularly true for materials of considerable thickness with a high thermal conductivity coefficient when cutting is performed at low speeds or with high abrasive consumption. The literature on the subject suggests that in AWJM there is little or no thermal energy effect on the microstructure of the material cut. The research described here involved the measurement of the cutting temperature with thermocouples placed at four different distances from the edge. The distances were measured using computed tomography inspection. The thermocouples used in the tests were capable of detecting temperatures of up to 100 °C. Locally, temperatures at the edge may reach much higher values. The results of the X-ray diffraction qualitative phase analysis reveal that locally the temperatures may be much higher than the eutectoid temperature. Phase changes occurred along the edge since austenite was observed. This suggests that the temperature in the jet impact zone was much higher than the eutectoid temperature. Optical microscopy was also employed to study the material microstructure. Finally, the material nanohardness was determined. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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16 pages, 2845 KiB

Open AccessArticle

Sequential Smoothing Treatment of Glass Workpieces Cut by Abrasive Water Jet

by Marzena Sutowska, Czesław Łukianowicz and Monika Szada-Borzyszkowska

Materials 2022, 15(19), 6894; https://doi.org/10.3390/ma15196894 - 5 Oct 2022

Cited by 9 | Viewed by 5120

Abstract

A centrifugal disc and vibratory finishing machines were applied to improve the surface texture of soda-lime workpieces cut by an abrasive water jet. This innovative method was denoted as sequential smoothing treatment. An experimental study of the effect of the smoothing process conditions [...] Read more.

A centrifugal disc and vibratory finishing machines were applied to improve the surface texture of soda-lime workpieces cut by an abrasive water jet. This innovative method was denoted as sequential smoothing treatment. An experimental study of the effect of the smoothing process conditions on the surface roughness, surface texture and micro roughness of the surface of glass workpieces was conducted. The analysis of the results obtained from experimental research made it possible to determine the optimum conditions for the smoothing process of glass workpieces after abrasive water jet cutting process. The proper selection of the finishing machine, machining media (abrasive chips) and compounds (liquids and powders) made it possible to reduce the surface roughness of areas located in the lower part of the cutting zone from Sa = 4.81 μm to Sa = 1.9 μm. The experimental results obtained confirmed the validity of using finishing machines to improve the surface quality of the soda-lime glass components. An important problem that requires further research is the increase in productivity and the reduction in machining time. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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20 pages, 8881 KiB

Open AccessArticle

Assessment of the Influence of Selected Technological Parameters on the Morphology Parameters of the Cutting Surfaces of the Hardox 500 Material Cut by Abrasive Water Jet Technology

by Tibor Krenicky, Stefania Olejarova and Milos Servatka

Materials 2022, 15(4), 1381; https://doi.org/10.3390/ma15041381 - 13 Feb 2022

Cited by 13 | Viewed by 1908

Abstract

This article deals with the evaluation of selected aspects of abrasive water jet technology (AWJ) in the cutting of abrasion-resistant steel (HARDOX 500) with a thickness of 40 mm. The high abrasion resistance as a typical significant property of this steel ranks it [...] Read more.

This article deals with the evaluation of selected aspects of abrasive water jet technology (AWJ) in the cutting of abrasion-resistant steel (HARDOX 500) with a thickness of 40 mm. The high abrasion resistance as a typical significant property of this steel ranks it among the special materials that are increasingly used. As the AWJ is a multiparametric technology, selected levels of feed rate, abrasive mass flow and pump working pressure were used in the experiments from the spectrum of technological parameters. For the purposes of evaluation, the examined cut surfaces were documented by a modified photographic method of displaying the cut surface by means of side lighting on the untreated cutting surface. The experimental part evaluates the dependences of selected cutting surface quality parameters (surface roughness and abrasive water jet deflection) on selected important technological parameters of the production system with AWJ technology (abrasive mass flow, technological head feed rate and pump working pressure). Based on the evaluation of the experiments, regression models were created to interpolate and extrapolate data to compare or supplement existing solutions in the field of research and as a basis for optimizing operating costs and increasing the efficiency of production systems with abrasive water jet technology. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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11 pages, 2876 KiB

Open AccessArticle

Analyses of Vibration Signals Generated in W. Nr. 1.0038 Steel during Abrasive Water Jet Cutting Aimed to Process Control

by Martin Tyč, Irena M. Hlaváčová and Pavel Barták

Materials 2022, 15(1), 345; https://doi.org/10.3390/ma15010345 - 4 Jan 2022

Cited by 6 | Viewed by 1752

Abstract

The presented research was aimed at finding a suitable tool and procedure for monitoring undercuts or other problems such as cutting without abrasive or inappropriate parameters of the jet during the abrasive water jet (AWJ) cutting of hard-machined materials. Plates of structural steel [...] Read more.

The presented research was aimed at finding a suitable tool and procedure for monitoring undercuts or other problems such as cutting without abrasive or inappropriate parameters of the jet during the abrasive water jet (AWJ) cutting of hard-machined materials. Plates of structural steel RSt 37-2 of different thickness were cut through by AWJ with such traverse speeds that cuts of various qualities were obtained. Vibrations of the workpiece were monitored by three accelerometers mounted on the workpiece by a special block that was designed for this purpose. After detecting and recording vibration signals through the National Instruments (NI) program Signal Express, we processed this data by means of the LabVIEW Sound and Vibration Toolkit. Statistical evaluation of data was performed, and RMS was identified as the parameter most suitable for online vibration monitoring. We focus on the analysis of the relationship between the RMS and traverse speed. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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12 pages, 4974 KiB

Open AccessArticle

Impact of Preparation of Titanium Alloys on Their Abrasive Water Jet Machining

by Adam Štefek and Martin Tyč

Materials 2021, 14(24), 7768; https://doi.org/10.3390/ma14247768 - 16 Dec 2021

Cited by 3 | Viewed by 2192

Abstract

Several titanium alloys, i.e., grade 2 Ti, Ti6Al4V and NiTi alloy, prepared by selected deformation procedures were subjected to abrasive water jet (AWJ) cutting and subsequently analysed. The study describes samples’ preparations and respective material structures. The impact of deformation processing of the [...] Read more.

Several titanium alloys, i.e., grade 2 Ti, Ti6Al4V and NiTi alloy, prepared by selected deformation procedures were subjected to abrasive water jet (AWJ) cutting and subsequently analysed. The study describes samples’ preparations and respective material structures. The impact of deformation processing of the selected alloys on the declination angle during cutting, and the results of measurements of surface wall quality performed for the selected samples at the Department of Physics of Faculty of Electrical Engineering and Computer Science at VŠB–Technical University of Ostrava, are presented and discussed, as are also the influences of structural features of the processed titanium alloys on surface qualities of the investigated samples. The results showed that the highest resistance to AWJ machining exhibited the Ti6Al4V alloy prepared by forward extrusion. Its declination angle (recalculated to the thickness 10 mm to compare all the studied samples) was 12.33° at the traverse speed of 100 mm/min, pumping pressure of 380 MPa, and abrasive mass flow rate of 250 g/min. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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16 pages, 7508 KiB

Open AccessArticle

Influence of Local Temperature Changes on the Material Microstructure in Abrasive Water Jet Machining (AWJM)

by Sławomir Spadło, Damian Bańkowski, Piotr Młynarczyk and Irena M. Hlaváčová

Materials 2021, 14(18), 5399; https://doi.org/10.3390/ma14185399 - 18 Sep 2021

Cited by 10 | Viewed by 2195

Abstract

This article considers effects of local heat transfer taking place insteel cutting by abrasive water jet machining (AWJM). The influence of temperature changes during AWJM has not been investigated thoroughly. Most studies on AWJM suggest that thermal energy has little or no effect [...] Read more.

This article considers effects of local heat transfer taking place insteel cutting by abrasive water jet machining (AWJM). The influence of temperature changes during AWJM has not been investigated thoroughly. Most studies on AWJM suggest that thermal energy has little or no effect on the material cut. This study focused on the analysis of the material microstructure and indentation microhardness in the jet impact zone and the adjacent area. The structure features revealed through optical metallography and scanning microscopy suggest local temperature changes caused by the impact of the abrasive water jet against the workpiece surface. From the microscopic examinationand hardness tests, it is clear that, during the process, large amounts of energy were transferred locally. The mechanical stress produced by the water jet led to plastic deformation at and near the surface. This was accompanied by the generation and transfer of large amounts of heat resulting in a local rise in temperature to 450 °C or higher. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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12 pages, 18717 KiB

Open AccessCommunication

A Short Note about the Impact Action of a Water Jet Stabilized by a Coaxial Air Stream in the Air and Underwater

by Josef Poláček, Irena Marie Hlaváčová and Martin Tyč

Materials 2021, 14(17), 5015; https://doi.org/10.3390/ma14175015 - 2 Sep 2021

Cited by 3 | Viewed by 2085

Abstract

A new original method, applying a coaxial protective airflow, was tested aiming to improve the pure water jet efficiency in surface layer removal or medium hard materials cutting or blasting. The dual action of the air flow is expected: the air co-flowing the [...] Read more.

A new original method, applying a coaxial protective airflow, was tested aiming to improve the pure water jet efficiency in surface layer removal or medium hard materials cutting or blasting. The dual action of the air flow is expected: the air co-flowing the water jet with approximately the same velocity should prevent the central jet from breaking up into tiny droplets in the near field, and simultaneously, it should support jet decomposition into big parts with enough destructive potential in the far-field. A brief survey of the relevant literature dealing with the water jet instability is presented, introducing four recognized breakup regimes. An original cutting head designed to generate a waterjet surrounded by protective coaxial air flow is introduced. The submitted device is supposed to operate within the first wind-induced regime. Two types of experiments, consisting of blasting limestone bricks placed either in the air or underwater, were realized. The depths of kerfs produced with different water pressures and air overpressures were evaluated. While no substantial positive effect was recognized in the air performance, the submerged blasting of the same material under similar conditions appeared to be promising. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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15 pages, 4316 KiB

Open AccessArticle

Investigation of Significant Parameters during Abrasive Waterjet Turning

by Adam Štefek, Jan Raška, Libor M. Hlaváč and Sławomir Spadło

Materials 2021, 14(16), 4389; https://doi.org/10.3390/ma14164389 - 5 Aug 2021

Cited by 4 | Viewed by 1745

Abstract

This paper presents an investigation of abrasive waterjet turning (AWJT). The purpose of the article was to investigate significant parameters of the turning process and to evaluate their impact on the turning product. The influence of the traverse speed, the rotational speed, and [...] Read more.

This paper presents an investigation of abrasive waterjet turning (AWJT). The purpose of the article was to investigate significant parameters of the turning process and to evaluate their impact on the turning product. The influence of the traverse speed, the rotational speed, and the relative position of the jet to the specimen (lateral jet shift) were investigated. Based on the previous research done in this field, the multi-pass tangential turning method was selected. Rotational speed does not seem to have a significant impact on the AWJ turning process. However, the relative position of the jet is a key parameter for improving the efficiency of the process. Increasing the lateral jet shift causes the volume of the material removed to increase until the optimal impact angle is reached. These findings need to be extended in order to adjust AWJT. Without these improvements, a comparison of jet to traditional technologies is inappropriate. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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15 pages, 6267 KiB

Open AccessFeature PaperArticle

Water Jet Technology: Experimental Verification of the Input Factors Variation Influence on the Generated Vibration Levels and Frequency Spectra

by Stefania Olejarova and Tibor Krenicky

Materials 2021, 14(15), 4281; https://doi.org/10.3390/ma14154281 - 31 Jul 2021

Cited by 15 | Viewed by 2084

Abstract

Vibration measurement belongs amongst the most important activities for the correct and stable operation of machines in terms of quality, economy, and safety. Monitoring the condition of the machine provides the key data for the detection of machine parts damage, thus preventing unexpected [...] Read more.

Vibration measurement belongs amongst the most important activities for the correct and stable operation of machines in terms of quality, economy, and safety. Monitoring the condition of the machine provides the key data for the detection of machine parts damage, thus preventing unexpected failure states and production drop-outs. Therefore, special attention is paid in the paper to the measurement and evaluation of basic parameters of vibration, particularly the frequency of vibrations and the amplitude of vibration acceleration. Experimental measurements were performed while machining the material HARDOX 500/10 on a production system using the abrasive water jet technology (AWJ) with the varied abrasive mass flow and the feed rate. By evaluating the results of measurements, recommendations of suitable and inappropriate combinations of operating parameters were formulated, widening current knowledge in the field of the abrasive parameters and the speed of movement of the technological head influence the amplitudes of vibration acceleration in the operation of production systems with AWJ technology. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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16 pages, 8871 KiB

Open AccessArticle

Revised Model of Abrasive Water Jet Cutting for Industrial Use

by Libor M. Hlaváč

Materials 2021, 14(14), 4032; https://doi.org/10.3390/ma14144032 - 19 Jul 2021

Cited by 20 | Viewed by 3035

Abstract

Research performed by the author in the last decade led him to a revision of his older analytical models used for a description and evaluation of abrasive water jet (AWJ) cutting. The review has shown that the power of 1.5 selected for the [...] Read more.

Research performed by the author in the last decade led him to a revision of his older analytical models used for a description and evaluation of abrasive water jet (AWJ) cutting. The review has shown that the power of 1.5 selected for the traverse speed thirty years ago was influenced by the precision of measuring devices. Therefore, the correlation of results calculated from a theoretical model with the results of experiments performed then led to an increasing of the traverse speed exponent above the value derived from the theoretical base. Contemporary measurements, with more precise devices, show that the power suitable for the traverse speed is essentially the same as the value derived in the theoretical description, i.e., it is equal to “one”. Simultaneously, the replacement of the diameter of the water nozzle (orifice) by the focusing (abrasive) tube diameter in the respective equations has been discussed, because this factor is very important for the AWJ machining. Some applications of the revised model are presented and discussed, particularly the reduced forms for a quick recalculation of the changed conditions. The correlation seems to be very good for the results calculated from the present model and those determined from experiments. The improved model shows potential to be a significant tool for preparation of the control software with higher precision in determination of results and higher calculation speed. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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19 pages, 4824 KiB

Open AccessArticle

Abrasive Waterjet (AWJ) Forces—Potential Indicators of Machining Quality

by Libor M. Hlaváč, Massimiliano P.G. Annoni, Irena M. Hlaváčová, Francesco Arleo, Francesco Viganò and Adam Štefek

Materials 2021, 14(12), 3309; https://doi.org/10.3390/ma14123309 - 15 Jun 2021

Cited by 7 | Viewed by 2382

Abstract

The necessity of monitoring the abrasive waterjet (AWJ) processes increases with the spreading of this tool into the machining processes. The forces produced on the workpiece during the abrasive waterjet machining can yield some valuable information. Therefore, a special waterjet-force measuring device designed [...] Read more.

The necessity of monitoring the abrasive waterjet (AWJ) processes increases with the spreading of this tool into the machining processes. The forces produced on the workpiece during the abrasive waterjet machining can yield some valuable information. Therefore, a special waterjet-force measuring device designed and produced in the past has been used for the presented research. It was tested during the AWJ cutting processes, because they are the most common and the best described up-to-date AWJ applications. Deep studies of both the cutting process and the respective force signals led to the decision that the most appropriate indication factor is the tangential-to-normal force ratio (TNR). Three theorems concerning the TNR were formulated and investigated. The first theorem states that the TNR strongly depends on the actual-to-limit traverse speed ratio. The second theorem claims that the TNR relates to the cutting-to-deformation wear ratio inside the kerf. The third theorem states that the TNR value changes when the cutting head and the respective jet axis are tilted so that a part of the jet velocity vector projects into the traverse speed direction. It is assumed that the cutting-to-deformation wear ratio increases in a certain range of tilting angles of the cutting head. This theorem is supported by measured data and can be utilized in practice for the development of a new method for the monitoring of the abrasive waterjet cutting operations. Comparing the tilted and the non-tilted jet, we detected the increase of the TNR average value from 1.28 ± 0.16 (determined for the declination angle 20° and the respective tilting angle 10°) up to 2.02 ± 0.25 (for the declination angle 30° and the respective tilting angle of 15°). This finding supports the previously predicted and published assumptions that the tilting of the cutting head enables an increase of the cutting wear mode inside the forming kerf, making the process more efficient. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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16 pages, 3715 KiB

Open AccessEditor’s ChoiceArticle

Abrasive Waterjet (AWJ) Forces—Indicator of Cutting System Malfunction

by Libor M. Hlaváč, Damian Bańkowski, Daniel Krajcarz, Adam Štefek, Martin Tyč and Piotr Młynarczyk

Materials 2021, 14(7), 1683; https://doi.org/10.3390/ma14071683 - 29 Mar 2021

Cited by 9 | Viewed by 2544

Abstract

Measurements enabling the online monitoring of the abrasive waterjet (AWJ) cutting process are still under development. This paper presents an experimental method which can be applicable for the evaluation of the AWJ cutting quality through the measurement of forces during the cutting process. [...] Read more.

Measurements enabling the online monitoring of the abrasive waterjet (AWJ) cutting process are still under development. This paper presents an experimental method which can be applicable for the evaluation of the AWJ cutting quality through the measurement of forces during the cutting process. The force measuring device developed and patented by our team has been used for measurement on several metal materials. The results show the dependence of the cutting to deformation force ratio on the relative traverse speed. Thus, the force data may help with a better understanding the interaction between the abrasive jet and the material, simultaneously impacting the improvement of both the theoretical and empirical models. The advanced models could substantially improve the selection of suitable parameters for AWJ cutting, milling or turning with the desired quality of product at the end of the process. Nevertheless, it is also presented that force measurements may detect some undesired effects, e.g., not fully penetrated material and/or some product distortions. In the case of a proper designing of the measuring device, the force measurement can be applied in the online monitoring of the cutting process and its continuous control. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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Review

Jump to: Research

75 pages, 63359 KiB

Open AccessReview

Abrasive Waterjet Machining

by Mohamed Hashish

Materials 2024, 17(13), 3273; https://doi.org/10.3390/ma17133273 - 2 Jul 2024

Cited by 1 | Viewed by 2408

Abstract

The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A [...] Read more.

The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A description of this process and its influencing parameters are first presented in this paper, along with process models for the AWJ tool itself and also for the jet–material interaction. The AWJ material removal process occurs through the high-velocity impact of abrasive particles, whose tips micromachine the material at the microscopic scale, with no thermal or mechanical adverse effects. The macro-characteristics of the cut surface, such as its taper, trailback, and waviness, are discussed, along with methods of improving the geometrical accuracy of the cut parts using these attributes. For example, dynamic angular compensation is used to correct for the taper and undercut in shape cutting. The surface finish is controlled by the cutting speed, hydraulic, and abrasive parameters using software and process models built into the controllers of CNC machines. In addition to shape cutting, edge trimming is presented, with a focus on the carbon fiber composites used in aircraft and automotive structures, where special AWJ tools and manipulators are used. Examples of the precision cutting of microelectronic and solar cell parts are discussed to describe the special techniques that are used, such as machine vision and vacuum-assist, which have been found to be essential to the integrity and accuracy of cut parts. The use of the AWJ machining process was extended to other applications, such as drilling, boring, milling, turning, and surface modification, which are presented in this paper as actual industrial applications. To demonstrate the versatility of the AWJ machining process, the data in this paper were selected to cover a wide range of materials, such as metal, glass, composites, and ceramics, and also a wide range of thicknesses, from 1 mm to 600 mm. The trends of Industry 4.0 and 5.0, AI, and IoT are also presented. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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47 pages, 30608 KiB

Open AccessReview

A Review of Waterjet Cutting Research towards microAWJ and the Definition of the Waterjet Digital Twin

by Massimiliano Annoni

Materials 2024, 17(6), 1328; https://doi.org/10.3390/ma17061328 - 13 Mar 2024

Cited by 1 | Viewed by 1866

Abstract

This review paper aimed to draw the red line passing through almost 25 years of research on waterjet cutting carried out at WJ_Lab, the waterjet laboratory of the Department of Mechanical Engineering of Politecnico di Milano. The purpose was not to just historically [...] Read more.

This review paper aimed to draw the red line passing through almost 25 years of research on waterjet cutting carried out at WJ_Lab, the waterjet laboratory of the Department of Mechanical Engineering of Politecnico di Milano. The purpose was not to just historically analyse the obtained scientific results by themselves but to make them even more useful by introducing the concept of the waterjet digital twin passing through the accuracy improvements due to microAWJ. This strategy effectively creates synergy among the topics and gives the opportunity to researchers in this field to both have an example of how research in industrial manufacturing processes can be guided by scientific and industrial needs, at least from the author’s point of view, and to appreciate how it can be made useful for further improvements by introducing a powerful concept as the digital twin. Full article

(This article belongs to the Special Issue Advanced Technology of Material Processing: Abrasive Water Jet Machining)

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