Surface geometric parameters proposal for the advanced control of abrasive waterjet technology

The paper deals with a proposal for surface geometric parameters for advanced quality control of abrasive waterjet technology according to the results obtained by means of non-contact optical shadow method. The main emphasis is put on the analysis of results for defining the process for prediction of new surface creation generated by the set of the abrasive waterjet factors stream of abrasive waterjet, including its geometric parameters. By means of decomposition of measured surface profile according to the root mean square parameter, in four topographical different zones the initial zone, the smooth zone, the transition zone and the rough zone new possibilities for evaluation of the surface quality and optimizing the selected technological factors of the cutting process and their control through the proposed databank conceptual structure are presented. This report deals with the problems of selecting and proposing an acceptable method for surface quality control which is available for continuous measurement and production.     

Topographical anomaly on surfaces created by abrasive waterjet

In the present study, real topographic function and maximal depth of neglected initial zone were analytically developed to predict surface roughness on the top region of surfaces created by abrasive waterjet. An upper area of workpieces was analysed in details. Experimentally created surfaces were measured by HOMMEL TESTER T8000 and non-contact profilometer Micro Prof FRT. As an experimental material, stainless steel AISI 304, AISI 309 and aluminium with a thickness of 10?mm have been used. On the basis of analysis and interpretation of data obtained from the surface, a topography function Ra _d , which is necessary to be known for the subsequent prediction and control of abrasive waterjet cutting technology, is derived. In the framework of interpretation of measured values, relations among these parameters are systematically analysed and physico-mechanical and distributional principles governing these parameter are formulated newly. Results are very important for further estimation of analytical expression of the real topographic function for any surface created by abrasive waterjet cutting.     

Determination of technologically optimal factors of modulated waterjet

This paper deals with two methods of determination of technologically optimal factors of a hydrodynamic resonance system leading to the acquiring of maximal fundamental frequency, amplitude, pressure, and energy of oscillations of a liquid jet. These factors are determined by the differential method and the method of state space search into depth. Furthermore, theoretically predicted results are presented, interpreted, and compared with results of laboratory measurements. The benefit of the study is the optimization itself, either for the optimal input factors of the prototype or a maximum possible modification of existing equipment in order to achieve the highest possible material disintegration efficiency.     

Experimental analysis of irregularities of metallic surfaces generated by abrasive waterjet

Experimental study of the surface quality produced by abrasive waterjet (AWJ) on metallic materials has been performed. The surface roughness/waviness was quantitatively evaluated by using the contactless optical measurement. In order to characterize the cut surface qualities, a single-parameter criterion has been proposed. Based on root mean square (RMS) roughness evaluation of the worst cut surface zone, the dimensionless statistical parameter C can be calculated as a basic quantity for AWJ surface cut characterization. As it was approved, besides its dependency on depth of AWJ trace, the value of C-parameter for the specific material is noticeably related also to the traverse speed of the cutting head. Such a relationship can be potentially used for adjusting the cutting speed of the machining process.     

Multi response optimization of process parameters based on Taguchi��Fuzzy model for coal cutting by water jet technology

The process of material cutting and fracture by high velocity water jets is a complex series of phenomena which may involve compression, tension, shear, erosion, wears, cracking, wave propagation, and cavitations damage. This makes the exact analysis of the jet cutting process to be very complicated. The problem of water jet coal cutting is a multiresponse problem. There are two output variables, depth of cut and cutting width whose optimization will result in the increase in the productivity of coal cutting. In this paper, a Taguchi?CFuzzy decision method has been used to determine the effective process parameters for improving the productivity of coal mines. The Taguchi method of experimental design is a widely accepted technique used for producing high quality products at low cost. The optimization of multiple responses in complex processes is common; therefore, to reduce the degree of uncertainty during the decision making, fuzzy rule-based reasoning was integrated with the Taguchi loss function.     

Determination of layer thickness in direct metal deposition using dimensional analysis

Direct Metal Deposition (DMD) is a blown powder laser deposition process that can be used to quickly produce fully dense metallic parts and to repair or modify high-value components. This paper illustrates the use of dimensional analysis to develop a mathematical model for the control of layer deposition in DMD. A brief explanation of the material deposition process is presented and the factors affecting the metal deposition is identified so that they can be used in modeling the height of the metal deposited. The validity of the generalized model is verified from experimental data of H13 steel and Ti material and it is found in good agreement with experimental findings.     

Using the acoustic sound pressure level for quality prediction of surfaces created by abrasive waterjet

The paper deals with an innovative way of cutting materials by abrasive waterjet with a view to increase its quality. In the research work, we were concerned with the search for a relationship between surface roughness and noise in the abrasive waterjet cutting process. Innovation lies in the use of negative characteristic of the technology—noise, which is a carrier of information about the quality of cutting process. In this way, the noise can be positively used in the on-line control of the technological process. The final result is a project for control of the process of abrasive waterjet cutting of materials by means of feedback according to the on-line measurement of acoustic pressure level L _aeq (dB). Instantaneous information about the state of cut according to the instantaneous value of L _aeq amplitude allows the automatic regulation of traverse speed of cutting head v _p (mm.min^?1), which is, together with the pressure p (MPa), one of the most important technological factors of control of production technology from the point of view of economic indicators and qualitative indicators of a semiproduct. The proposed model has been experimentally verified and was simulated in Matlab.     

Characterization of Failure Behavior in Distorted WC-Co Tip of Coal Mining Picks

Journal of Failure Analysis and Prevention - The present paper deals with the characterization of failure behavior in the cemented carbide (WC 94–Co 6%) tips of two cutters, i.e., conical...