Experimental investigation and modelling of the kerf profile in submerged milling by macro abrasive waterjet

IF 2.4 3区 工程技术 Q3 ENGINEERING, MANUFACTURING
R. Ravi, Deepu Kumar T. N., D. Srinivasu
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引用次数: 0

Abstract

Towards achieving control over the kerfing through abrasive waterjet submerged milling, there is a need to (i) understand the influence of the water column height on the kerf quality and (ii) develop a model for the prediction of the kerf characteristics. This study performs detailed experimentation to assess the kerf quality enhancement in submerged milling relative to the in-air on Al6061. From the modelling perspective, there are very limited efforts in developing a comprehensive model that includes both the jet flow dynamics and material removal models - this is the missing link. Towards this, a comprehensive model is proposed and validated for the prediction of kerf in in-air and submerged conditions by considering (i) jet dynamics and (ii) jet-material interaction. From the experimental results, it is observed that by adopting the submerged milling, the damaged region, top kerf width and edge radius got reduced by 20.3%, 13.53%, and 22.7%, respectively. However, this enhancement in the kerf quality is associated with a reduction in the centreline erosion depth (hmax) by 12.33% and a material removal rate by 24.52%. The material removal mechanism is more uniform and directed in the submerged milling, whereas in-air is random. The proposed model predicted the kerf cross-sectional profile in submerged milling and in-air with a mean absolute error of 60 μm and 57 μm, squared Pearson correlation coefficient of 0.97 and 0.99, and the hmax with a maximum error of 1.3% and 1.4%.
大磨料水射流埋铣切口轮廓的实验研究与建模
为了通过磨料水射流浸没式铣削实现对切口的控制,需要(i)了解水柱高度对切口质量的影响,以及(ii)开发用于预测切口特性的模型。本研究进行了详细的实验,以评估在Al6061上相对于空气中铣削的切口质量增强。从建模的角度来看,开发一个包括射流动力学和材料去除模型的综合模型的努力非常有限——这是缺失的一环。为此,通过考虑(i)射流动力学和(ii)射流-材料相互作用,提出并验证了一个综合模型,用于预测空气和水下条件下的切口。实验结果表明,采用浸没铣削,损伤区域、切口宽度和边缘半径分别减少了20.3%、13.53%和22.7%。然而,切口质量的提高与中心线侵蚀深度(hmax)减少12.33%和材料去除率减少24.52%有关。材料去除机制在浸没式铣削中更为均匀和直接,而在空气中则是随机的。所提出的模型预测了埋铣和空气中的切口截面轮廓,平均绝对误差分别为60μm和57μm,Pearson平方相关系数分别为0.97和0.99,hmax最大误差分别为1.3%和1.4%。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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来源期刊
CiteScore
6.80
自引率
20.00%
发文量
126
审稿时长
12 months
期刊介绍: Areas of interest including, but not limited to: Additive manufacturing; Advanced materials and processing; Assembly; Biomedical manufacturing; Bulk deformation processes (e.g., extrusion, forging, wire drawing, etc.); CAD/CAM/CAE; Computer-integrated manufacturing; Control and automation; Cyber-physical systems in manufacturing; Data science-enhanced manufacturing; Design for manufacturing; Electrical and electrochemical machining; Grinding and abrasive processes; Injection molding and other polymer fabrication processes; Inspection and quality control; Laser processes; Machine tool dynamics; Machining processes; Materials handling; Metrology; Micro- and nano-machining and processing; Modeling and simulation; Nontraditional manufacturing processes; Plant engineering and maintenance; Powder processing; Precision and ultra-precision machining; Process engineering; Process planning; Production systems optimization; Rapid prototyping and solid freeform fabrication; Robotics and flexible tooling; Sensing, monitoring, and diagnostics; Sheet and tube metal forming; Sustainable manufacturing; Tribology in manufacturing; Welding and joining
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