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

Materials ◽  
2021 ◽  
Vol 14 (7) ◽  
pp. 1683
Author(s):  
Libor M. Hlaváč ◽  
Damian Bańkowski ◽  
Daniel Krajcarz ◽  
Adam Štefek ◽  
Martin Tyč ◽  
...  
Keyword(s):  
Online Monitoring ◽  
Force Measurement ◽  
Traverse Speed ◽  
Cutting Process ◽  
Abrasive Waterjet ◽  
Continuous Control ◽  
Measuring Device ◽  
Force Ratio ◽  
Deformation Force ◽  
Awj Cutting

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.

scholarly journals Influence of Material Structure on Forces Measured during Abrasive Waterjet (AWJ) Machining

Materials ◽  
2020 ◽  
Vol 13 (17) ◽  
pp. 3878 ◽  
Author(s):  
Libor M. Hlaváč ◽  
Adam Štefek ◽  
Martin Tyč ◽  
Daniel Krajcarz
Keyword(s):  
Material Properties ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Material Structure ◽  
Machining Efficiency ◽  
Force Measurements ◽  
Material Response ◽  
Factors Influencing ◽  
Force Ratio ◽  
Deformation Force

Material structure is one of the important factors influencing abrasive waterjet (AWJ) machining efficiency and quality. The force measurements were performed on samples prepared from two very similar steels with different thicknesses and heat treatment. The samples were austenitized at 850 °C, quenched in polymer and tempered at various temperatures between 20 °C and 640 °C. The resulting states of material substantially differed in strength and hardness. Therefore, samples prepared from these material states are ideal for testing of material response to AWJ. The force measurements were chosen to test the possible influence of material structure on the material response to the AWJ impact. The results show that differences in material structure and respective material properties influence the limit traverse speed. The cutting to deformation force ratio seems to be a function of relative traverse speed independently on material structure.

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

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3309
Author(s):  
Libor M. Hlaváč ◽  
Massimiliano P. G. Annoni ◽  
Irena M. Hlaváčová ◽  
Francesco Arleo ◽  
Francesco Viganò ◽  
...  
Keyword(s):  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Speed Ratio ◽  
Machining Processes ◽  
Measuring Device ◽  
Cutting Head ◽  
Wear Ratio ◽  
Tilting Angle ◽  
Declination Angle ◽  
Awj Cutting

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.

scholarly journals Basic abrasive waterjet cutting process parameters

2018 ◽  
Vol 19 (12) ◽  
pp. 654-657
Author(s):  
Sławomir Spadło ◽  
Daniel Krajcarz
Keyword(s):  
Water Pressure ◽  
Cutting Speed ◽  
Cutting Process ◽  
Machining Process ◽  
Abrasive Waterjet ◽  
Maximum Efficiency ◽  
Waterjet Cutting ◽  
Abrasive Waterjet Cutting ◽  
Water Jet Cutting ◽  
Awj Cutting

The article presents the basic parameters characterizing the abrasive water jet cutting, such as: water pressure (pw), cutting speed (vf), abrasive mass flow rate (ma) and the distance between forming nozzle and the cut material (l). Each of the mentioned parameters of the cutting process has been described in a separate subsection. The authors of the article focused primarily on the aspects related to the possibility of achieving maximum efficiency of the machining process while maintaining the assumed quality of cutting for individual cutting parameters. A detailed analysis of the topic was enabled the authors own research and an available literature on this subject. A closer understanding of the phenomena accompanying the abrasive waterjet cutting (AWJ) process and obtaining characteristics that would describe the influence of the tested output parameters in the function of input parameters will enable optimization of AWJ cutting process.

scholarly journals Proposal for a method of measurement and control of surface quality in the course of abrasive waterjet cutting of material

2019 ◽  
Vol 299 ◽  
pp. 02003
Author(s):  
Ján Kmec ◽  
Marta Harničárová ◽  
Cristina Borzan ◽  
Marian Borzan ◽  
Jan Valíček ◽  
...  
Keyword(s):  
Sound Pressure Level ◽  
Sound Pressure ◽  
Traverse Speed ◽  
Pressure Level ◽  
Production Optimization ◽  
Abrasive Waterjet ◽  
Continuous Control ◽  
Mean Values ◽  
Cutting Head ◽  
Functional Relations

The paper deals with the automation of the hydroabrasive production process, which leads to higher productivity and production optimization. In the submitted work, the basis of control design is a topography function of surface roughness of abrasive waterjet cut walls, and its functional relations to the controlled speed and to the measured mean values of sound pressure level, including a design of a suitable diagram of connections of controlling elements and equipment. The controlled parameter is the final roughness of a cut wall; in the design, the roughness is program-regulated according to the continuously measured root mean square of sound pressure level by means of continuous control of the traverse speed of cutting head.

scholarly journals Profile Cutting on Alumina Ceramics by Abrasive Waterjet. Part 1: Experimental Investigation

2006 ◽  
Vol 220 (5) ◽  
pp. 703-714 ◽  
Author(s):  
J Wang ◽  
H Liu
Keyword(s):  
Experimental Investigation ◽  
Performance Measures ◽  
Process Parameters ◽  
Cutting Performance ◽  
Cutting Process ◽  
Abrasive Waterjet ◽  
Depth Of Cut ◽  
Curvature Radius ◽  
Alumina Ceramics ◽  
Awj Cutting

An experimental investigation is presented of the various cutting performance measures, such as the kerf taper and depth of cut, in profile cutting on an 87 per cent alumina ceramic by abrasive waterjet (AWJ) over a wide range of process parameters. It is found that the taper angles on the two kerf walls produced in cutting AWJ of profiles are different in magnitude and exhibit different trends as the profile curvature radius varies. Moreover, the depth of cut increases with an increase in the curvature radius and approaches its maximum in straight cutting. The other process variables affect the cutting process in a way similar to that in straight cutting. Recommendations are finally made for the selection of process parameters in AWJ profile cutting of alumina ceramics. Predictive mathematical models for the major cutting performance measures that are essential for the optimization of the AWJ cutting process are reported in the subsequent part of this investigation.

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 Experimental Study on Grinding Force of Zirconia Ceramics in Dry/Wet Grinding Environment

2018 ◽  
Vol 198 ◽  
pp. 02004
Author(s):  
Junping Zhang ◽  
Weidong Wang ◽  
Songhua Li ◽  
Han Tao
Keyword(s):  
Grinding Force ◽  
Grinding Wheel ◽  
Feed Speed ◽  
Zirconia Ceramics ◽  
Grinding Forces ◽  
Measuring Device ◽  
Linear Speed ◽  
Wet Grinding ◽  
Dry Grinding ◽  
Force Ratio

The impacts of different linear speed of grinding wheel, grinding depth and workpiece feed speed with or without grinding fluid on grinding force were studied by plane grinding machining of zirconia ceramics. The impacts of different machining environment and grinding parameter on normal and tangential grinding forceswere studied by testing the grinding force during grinding with a force measuring device. The studies showed that the normal and tangential grinding forces decrease with the increase of the linear speed of grinding wheel and increase with the improvement of grinding depth and workpiece feed speed. The grinding depth has the greatest impacts on the normal and tangential grinding forces in dry grinding environment; while in wet grinding environment, the grinding depth exerts the greatest impacts on the normal grinding force and the linear speed of grinding wheel imposes the greatest impacts on the tangential grinding force. In addition, it was found that the normal grinding force in dry grinding is minor than that in wet grinding, that the tangential grinding force in dry grinding is greater than that in wet grinding, and that the grinding force ratio in dry grinding is lower than that in wet grinding.

scholarly journals Experimental Exploration of Hybrid Metal Matrix Composite using Abrasive Water Jet Machining

2019 ◽  
Vol 9 (2) ◽  
pp. 1872-1875
Author(s):  
Barath M ◽  
◽  
Rajesh S ◽  
Duraimurugan P ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Metal Matrix Composite ◽  
Matrix Composite ◽  
Metal Matrix ◽  
Water Pressure ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Force Microscopy ◽  
Business Applications ◽  
Hybrid Metal Matrix Composite

The abrasive mixed waterjet was with success utilized to chop several materials together with steel, metal and glass for a spread of business applications. This work focuses on surface roughness of hybrid metal matrix composite (AA6061, Al2O3, B4C). Machining was applied by AWJM (Abrasive Waterjet Cutting) at completely different parameters Water pressure, Traverse speed, Abrasive flow and stand-off distance. The reinforced composite was analyzed exploitation FE SEM (Field Emission Scanning lepton Microscope) and distribution of reinforced was studied by AFM (Atomic Force Microscopy). For optimum results surface roughness was calculated.

scholarly journals Experimental Analysis and Soft Computing Modeling of Abrasive Waterjet Milling of Steel Workpieces

2020 ◽  
Vol 318 ◽  
pp. 01031
Author(s):  
Panagiotis Karmiris-Obratański ◽  
Nikolaos E. Karkalos ◽  
Anastasios Tzotzis ◽  
Panagiotis Kyratsis ◽  
Angelos P. Markopoulos
Keyword(s):  
Soft Computing ◽  
Process Parameters ◽  
High Efficiency ◽  
Traverse Speed ◽  
Abrasive Waterjet ◽  
Machining Processes ◽  
Metalworking Industry ◽  
Complex Features ◽  
Alternative Processes ◽  
Conventional Machining

Conventional machining processes such as turning, milling and drilling have long been prominent in the metalworking industry but alternative processes which do not require the use of a cutting tool in order to conduct material removal have also been proven to be sufficiently capable of achieving high efficiency in various cases. In particular, Abrasive Waterjet (AWJ) machining can be regarded as a rather appropriate choice for cutting operations, taking into consideration that it involves no heat affected zones, is able to process all material types and create a variety of complex features with success. In the present work, a comprehensive study on the effect of four process parameters, namely jet traverse speed, stand-off distance, abrasive mass flow rate and jet pressure on the width and depth of machined slots on a steel workpiece is conducted. The results are first analyzed with statistical methods in order to determine the effect and the relative importance of each parameter on the produced width and depth of the slots. Finally, these results are used to develop soft computing predictive models based on Artificial Neural Networks (ANN), which can efficiently relate the process parameters with its outcome.

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