scholarly journals Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4192 ◽  
Author(s):  
Alejandro Sambruno ◽  
Fermin Bañon ◽  
Jorge Salguero ◽  
Bartolome Simonet ◽  
Moises Batista
Keyword(s):  
Carbon Fiber ◽  
Damage Zone ◽  
Cutting Parameters ◽  
Thermoplastic Composite ◽  
Abrasive Waterjet ◽  
Hydraulic Pressure ◽  
Carbon Fiber Composites ◽  
Abrasive Waterjet Machining ◽  
Kerf Taper ◽  
Waterjet Machining

Carbon fiber-reinforced thermoplastics (CFRTPs) are materials of great interest in industry. Like thermosets composite materials, they have an excellent weight/mechanical properties ratio and a high degree of automation in their manufacture and recyclability. However, these materials present difficulties in their machining due to their nature. Their anisotropy, together with their low glass transition temperature, can produce important defects in their machining. A process able to machine these materials correctly by producing very small thermal defects is abrasive waterjet machining. However, the dispersion of the waterjet produces a reduction in kinetic energy, which decreases its cutting capacity. This results in an inherent defect called a kerf taper. Also, machining these materials with reduced thicknesses can increase this defect due to the formation of a damage zone at the beginning of cut due to the abrasive particles. This paper studies the influence of cutting parameters on the kerf taper generated during waterjet machining of a thin-walled thermoplastic composite material (carbon/polyurethane, C/TPU). This influence was studied by means of an ANOVA statistical analysis, and a mathematical model was obtained by means of a response surface methodology (RSM). Kerf taper defect was evaluated using a new image processing methodology, where the initial and final damage zone was separated from the kerf taper defect. Finally, a combination of a hydraulic pressure of 3400 bar with a feed rate of 100 mm/min and an abrasive mass flow of 170 g/min produces the minimum kerf taper angle.

scholarly journals Impacts of Traverse Speed and Material Thickness on Abrasive Waterjet Contour Cutting of Austenitic Stainless Steel AISI 304L

2021 ◽  
Vol 11 (11) ◽  
pp. 4925
Author(s):  
Jennifer Milaor Llanto ◽  
Majid Tolouei-Rad ◽  
Ana Vafadar ◽  
Muhammad Aamir
Keyword(s):  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Taper Angle ◽  
Material Thickness ◽  
Abrasive Waterjet Machining ◽  
Kerf Taper ◽  
Waterjet Machining

Abrasive water jet machining is a proficient alternative for cutting difficult-to-machine materials with complex geometries, such as austenitic stainless steel 304L (AISI304L). However, due to differences in machining responses for varied material conditions, the abrasive waterjet machining experiences challenges including kerf geometric inaccuracy and low material removal rate. In this study, an abrasive waterjet machining is employed to perform contour cutting of different profiles to investigate the impacts of traverse speed and material thickness in achieving lower kerf taper angle and higher material removal rate. Based on experimental investigation, a trend of decreasing the level of traverse speed and material thickness that results in minimum kerf taper angle values of 0.825° for machining curvature profile and 0.916° for line profiles has been observed. In addition, higher traverse speed and material thickness achieved higher material removal rate in cutting different curvature radii and lengths in line profiles with obtained values of 769.50 mm3/min and 751.5 mm3/min, accordingly. The analysis of variance revealed that material thickness had a significant impact on kerf taper angle and material removal rate, contributing within the range of 69–91% and 62–69%, respectively. In contrast, traverse speed was the least factor measuring within the range of 5–18% for kerf taper angle and 27–36% for material removal rate.

scholarly journals Influence of Abrasive Waterjet Parameters on the Cutting and Drilling of CFRP/UNS A97075 and UNS A97075/CFRP Stacks

Materials ◽  
2018 ◽  
Vol 12 (1) ◽  
pp. 107 ◽  
Author(s):  
Raul Ruiz-Garcia ◽  
Pedro Mayuet Ares ◽  
Juan Vazquez-Martinez ◽  
Jorge Salguero Gómez
Keyword(s):  
Water Pressure ◽  
Abrasive Waterjet ◽  
Abrasive Waterjet Machining ◽  
Final Assembly ◽  
Reinforced Plastic ◽  
Kerf Taper ◽  
Waterjet Machining ◽  
Aeronautical Industry ◽  
Assembly Operations ◽  
Contour Machining

The incorporation of plastic matrix composite materials into structural elements of the aeronautical industry requires contour machining and drilling processes along with metallic materials prior to final assembly operations. These operations are usually performed using conventional techniques, but they present problems derived from the nature of each material that avoid implementing One Shot Drilling strategies that work separately. In this work, the study focuses on the evaluation of the feasibility of Abrasive Waterjet Machining (AWJM) as a substitute for conventional drilling for stacks formed of Carbon Fiber Reinforced Plastic (CFRP) and aluminum alloy UNS A97050 through the study of the influence of abrasive mass flow rate, traverse feed rate and water pressure in straight cuts and drills. For the evaluation of the straight cuts, Stereoscopic Optical Microscopy (SOM) and Scanning Electron Microscopy (SEM) techniques were used. In addition, the kerf taper through the proposal of a new method and the surface quality in different cutting regions were evaluated. For the study of holes, the macrogeometric deviations of roundness, cylindricity and straightness were evaluated. Thus, this experimental procedure reveals the conditions that minimize deviations, defects, and damage in straight cuts and holes obtained by AWJM.

Machinability Study of Hybrid FRP Composite Using Abrasive Waterjet Trimming Technology

2017 ◽  
Vol 740 ◽  
pp. 118-124 ◽  
Author(s):  
M.M.W. Irina ◽  
Azwan Iskandar Azmi ◽  
Chang Chuan Lee
Keyword(s):  
Surface Roughness ◽  
Thermal Sensitivity ◽  
Fiber Reinforcement ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Hydraulic Pressure ◽  
Abrasive Waterjet Machining ◽  
Frp Composite ◽  
Waterjet Machining ◽  
Conventional Machining

Machining of fiber reinforcement polymer (FRP) composite without any defect is extremely challenging when using conventional processes. This mainly due to its inherent anisotropic, heterogeneous, thermal sensitivity, and highly abrasive of nature of fiber reinforcement. Therefore, a kind of non-conventional machining process namely abrasive waterjet machining (AWJM) was endeavoured as it has been reported to be able to machine or cut almost any material included composites. In fact, previous research only provides partially desired parameters on machining these materials and mainly focuses on plain FRP composite. Therefore, this research attempted to evaluate the significant AWJM process parameters comprehensively on the main machinability output on the hybrid FRP composite. 2k factorial design and statistical analysis of variance (ANOVA) were applied to determine the performance of trimming process regarding surface roughness and delamination (entrance and exit). Experimental results revealed that the surface roughness was affected by the stand-off distance, abrasive flow rate, traverse rate rather than hydraulic pressure. Similar findings as to that of surface roughness were also observed for the top and bottom delamination damage.

scholarly journals Experimental Investigations into Abrasive Waterjet Machining of Carbon Fiber Reinforced Plastic

2015 ◽  
Vol 2015 ◽  
pp. 1-9 ◽  
Author(s):  
Prasad D. Unde ◽  
M. D. Gayakwad ◽  
N. G. Patil ◽  
R. S. Pawade ◽  
D. G. Thakur ◽  
...  
Keyword(s):  
Material Removal Rate ◽  
Fiber Orientation ◽  
Material Removal ◽  
Removal Rate ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Experimental Investigations ◽  
Abrasive Waterjet Machining ◽  
Kerf Taper ◽  
Waterjet Machining

Abrasive waterjet machining (AWJM) is an emerging machining process in which the material removal takes place due to abrasion. A stream of abrasive particles mixed with filtered water is subjected to the work surface with high velocity. The present study is focused on the experimental research and evaluation of the abrasive waterjet machining process in order to evaluate the technological factors affecting the machining quality of CFRP laminate using response surface methodology. The standoff distance, feed rate, and jet pressure were found to affect kerf taper, delamination, material removal rate, and surface roughness. The material related parameter, orientation of fiber, has been also found to affect the machining performance. The kerf taper was found to be 0.029 for 45° fiber orientation whereas it was 0.036 and 0.038 for 60° and 90°, respectively. The material removal rate is 18.95 mm3/sec for 45° fiber orientation compared to 18.26 mm3/sec for 60° and 17.4 mm3/sec for 90° fiber orientation. The Ra value for 45° fiber orientation is 4.911 µm and for 60° and 90° fiber orientation it is 4.927 µm and 4.974 µm, respectively. Delamination factor is found to be more for 45° fiber orientation, that is, 2.238, but for 60° and 90° it is 2.029 and 2.196, respectively.

Current Research Trends in Abrasive Waterjet Machining of Fiber Reinforced Composites

2012 ◽  
Vol 713 ◽  
pp. 37-42 ◽  
Author(s):  
D.K. Kalla ◽  
B. Zhang ◽  
R. Asmatulu ◽  
P.S. Dhanasekaran
Keyword(s):  
Cutting Parameters ◽  
Machining Process ◽  
Fiber Reinforced Polymer ◽  
Abrasive Waterjet ◽  
Fiber Reinforced ◽  
Frp Composites ◽  
Abrasive Waterjet Machining ◽  
Reinforced Polymer ◽  
Waterjet Machining ◽  
The Common

The use of fiber reinforced polymer (FRP) composites in the aircraft and automotive industries exponentially. Reinforced fibers which are abrasive in nature make it hard to machine by the traditional machining. Dissipation of heat into workpiece which in turn results in enhanced cutting tool wear and damage to the workpiece is the common problems faced in traditional machining of FRPs. Nontraditional machining is favorable to reduce these issues. Abrasive waterjet machining (AWJM) is one of the best choices for machining FRPs. Development in AWJM of FRPs and the current research in this field will be discussed in details. Machining process of FRPs, quality dependents such as surface finish and variable cutting parameters will be addressed. One of main issues in AWJM noise due to high flow rate of water jet will be addressed. The importance of human safety aspects when AWJM is employed will be highlighted. Limitations and challenges in AWJM are presented elaborately.

A Study of Kerf Characteristics in Abrasive Waterjet Machining of Graphite/Epoxy Composite

1996 ◽  
Vol 118 (2) ◽  
pp. 256-265 ◽  
Author(s):  
D. Arola ◽  
M. Ramulu
Keyword(s):  
Material Removal ◽  
Epoxy Composite ◽  
Cutting Parameters ◽  
Operating Conditions ◽  
Abrasive Waterjet ◽  
Abrasive Waterjet Machining ◽  
Initial Damage ◽  
Geometrical Features ◽  
Waterjet Machining ◽  
Laminate Thickness

Kerf geometry, kerf wall features, and cutting front characteristics of an Abrasive Waterjet (AWJ) machined Graphite/Epoxy (Gr/Ep) laminate were studied. A macroscopic analyses suggests that geometrical features associated with AWJ machining of Gr/Ep laminates are influenced by three macro regions along the cutting depth. The presence of these regions, including initial damage at jet entry, smooth cutting, and rough cutting near the jet exit, depends on the operating conditions. Design of experiments and analysis of variance were used to determine the effect of cutting parameters on kerf characteristics and to develop empirical models for kerf profile and features of the three distinct macroscopic regions. Cutting front analysis revealed that the mechanisms of material removal in AWJ machining of Gr/Ep do not change over the jet penetration depth. In general, high quality uniform cuts may be obtained by minimizing initial damage at the jet entry and by extending the smooth cutting region beyond the laminate thickness through the appropriate choice of cutting parameters.

scholarly journals Influence of Abrasive Waterjet Parameters on the Cutting and Drilling of CFRP/UNS A97075 and UNS A97075/CFRP Stacks

2018 ◽  
Author(s):  
Raúl Ruíz García ◽  
Pedro F. Mayuet ◽  
Juan Manuel Vázquez Martínez ◽  
Jorge Salguero Gómez
Keyword(s):  
Water Pressure ◽  
Abrasive Waterjet ◽  
Abrasive Waterjet Machining ◽  
Final Assembly ◽  
Reinforced Plastic ◽  
Kerf Taper ◽  
Waterjet Machining ◽  
Aeronautical Industry ◽  
Assembly Operations ◽  
Contour Machining

The incorporation of plastic matrix composite materials into structural elements of the aeronautical industry requires contour machining and drilling processes along with metallic materials prior to final assembly operations. These operations are usually performed using conventional techniques, but they present problems derived from the nature of each material that avoid implementing One Shot Drilling strategies that work separately. In this work, the study focuses on the evaluation of the feasibility of Abrasive Waterjet Machining (AWJM) as a substitute for conventional drilling for stacks formed of Carbon Fiber Reinforced Plastic (CFRP) and aluminum alloy UNS A97050 through the study of the influence of abrasive mass flow rate, traverse feed rate and water pressure in straight cuts and drills. For the evaluation of the straight cuts, Stereoscopic Optical Microscopy (SOM) and Scanning Electron Microscopy (SEM) techniques are used inspection techniques have been used. In addition, the kerf taper through the proposal of a new method and the surface quality in different cutting regions have been evaluated. For the study of holes, the macrogeometric deviations of roundness, cylindricity and straightness have been evaluated. Thus, this experimental procedure reveals the conditions that minimize deviations, defects, and damage in straight cuts and holes obtained by AWJM.

Abrasive Waterjet Cutting of Aluminum Alloys: Workpiece Surface Roughness

2013 ◽  
Vol 404 ◽  
pp. 3-9 ◽  
Author(s):  
Nihat Tosun ◽  
Ihsan Dagtekin ◽  
Latif Ozler ◽  
Ahmet Deniz
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Aluminum Alloys ◽  
Abrasive Waterjet ◽  
Traditional Methods ◽  
Workpiece Surface ◽  
Abrasive Waterjet Machining ◽  
Waterjet Machining ◽  
Area Of Application ◽  
Better Than

Abrasive waterjet machining is one of the non-traditional methods of the recent years which found itself a wide area of application in the industry for machining of different materials. In this paper, the surface roughness of 6061-T6 and 7075-T6 aluminum alloys are being cut with abrasive waterjet is examined experimentally. The experiments were conducted with different waterjet pressures and traverse speeds. It has been found that the surface roughness obtained by cutting material with high mechanical properties is better than that of obtained by cutting material with inferior mechanical properties.

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