CFD-aided prediction of the shape of abrasive slurry jet micro-machined channels in sintered ceramics

Kowsari, Kavin; Nouraei, H.; Samareh, B.; Papini, M.; Spelt, J.K.

doi:10.1016/j.ceramint.2016.01.091

Cited by 43 publications

(23 citation statements)

References 16 publications

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“…The waterjet flow domain was solved using ANSYS Fluent 15.0 (Ansys Inc., Cecil Township, PA, USA). A multiphase, transient, volume-of-fluid (VOF), k- shear-stress transport turbulence model was used for the waterjet surrounded by air [108,141]. The transient simulation used a 2 ns time step, which has been shown to be adequate to capture the hydraulic shock action [114].…”

Section: Cfd Modelmentioning

confidence: 99%

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Predicting Surface Roughness and Delamination When Abrasive Waterjet Machining Fiber Reinforced Polymer Composites

Schwartzentruber¹

2023

Preprint

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The machining of composite materials is difficult because of their non-homogenous structure and their constituents commonly possess a high resistance to cutting. Abrasive waterjet machining (AWJM) is more attractive for composite substrates than conventional machining techniques because of its ability to rapidly machine a wide variety of materials with low reactionary forces on the workpiece, and without creating a heat-affected zone. However, AWJM is prone to producing variable surface roughness and delamination. This dissertation aimed to model these surface roughness and delamination mechanisms. The thesis presents 2D and 3D roughness models capable of predicting the surface roughness during abrasive waterjet (AWJ) trimming of composite substrates. The models were able to predict the measured surface roughness with an average error of 10% and 16%, for the 2D and 3D models, respectively. The thesis also presents experimental and numerical results characterizing the delamination when AWJ piercing and cutting a carbon-fiber/epoxy laminate. Fluid-structure interaction (FSI) models created to simulate the piercing process showed that interlaminar delamination was due to the hydraulic shock (‘water hammer’) associated with liquid jet impact. As expected, increased pressure and nozzle size resulted in ply debonding, and was experimentally verified using 3D x-ray micro-tomography. The composite anisotropy was found to produce an asymmetric shock loading along the liquid-solid interface, which contributed to the asymmetric delamination. The FSI model showed that delamination when cutting carbon-fiber/epoxy depended primarily on the normal interlaminar stress, with relatively large damage zones occurring ahead of the cutting front. This trend was also observed in x-ray micro-tomographs of an AWJ cut. The amount of delamination across different process parameters was also measured using a moisture uptake methodology, and showed that increase traverse speed, increased nozzle size, and decreased abrasive flow rate, increased delamination. Prediction and characterization of surface roughness and delamination when AWJM will allow further improvement of cut-surface finish and structural integrity of composite materials, respectively

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Section: Cfd Modelmentioning

confidence: 99%

“…Following the AWJ modeling work of Liu et al [140], and Li et al [99] for compressibility of liquid drop impact (LDI), a multi-phase VOF model was used. The VOF model is capable of simulating free surface jet flows between various types of fluids, both liquid and gas [141],…”

Section: Cfd Modelmentioning

confidence: 99%

Predicting Surface Roughness and Delamination When Abrasive Waterjet Machining Fiber Reinforced Polymer Composites

Schwartzentruber¹

2023

Preprint

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“…However, such methods inevitably result in damage such as micro-cracks. ASJM has the potential to be a relatively inexpensive technology for machining ceramics, but there is still a significant amount work required for its implementation [17,18]. In addition, rotary ultrasonic machining has the potential to achieve high material removal rates and result in relatively low surface damage and strength degradation.…”

Section: Introductionmentioning

confidence: 99%

Experimental Study on Machining Engineering Ceramics by Electrochemical Discharge Compound Grinding

Zhang

Yang

et al. 2019

Materials

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Since engineering ceramics have many characteristics, including hardness, brittleness, and high melting point, traditional machining methods can no longer play a useful role in precision machining. Based on this situation, a platform of electrochemical discharge compound mechanical grinding was constructed and is presented in this paper, and machining experiments of micro-grooves were carried out in alumina ceramics. Grooves were observed by scanning electron microscope (SEM), and the morphology and the groove width of micro-grooves under different machining parameters were compared and analyzed. Furthermore, in order to study the improvement effect of mechanical grinding on machining quality, the surface roughness of micro-grooves was measured by a confocal material microscope. The results show that as the pulse power supply voltage increases or the frequency decreases, the width of the micro-grooves increases, and the morphology of the micro-grooves first improves and then deteriorates. With the increase of tool electrode rotation speed, the width of micro-grooves first increases and then remains unchanged, and the morphology and the surface roughness of micro-grooves first improves and then remains stable. Finally, the optimal parameters (power voltage of 20 V, pulse frequency of 400 Hz, electrode rotation speed of 600 rpm) were chosen to machine micro-grooves with good quality.

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“…1,2 The behavior of waterjet-machined ceramics has been reported by numerous research works. 3,4 But only a few research studies focus on the machinability of ceramic-matrix composites machined by waterjet. 5 E. Savrun et al 6 reported on the feasibility of finishing a SiC whisker/Al 2 O 3 composite with an abrasive waterjet.…”

Section: Introductionmentioning

confidence: 99%

Piercing behavior of an in-situ Cf/Al2O3 composite in waterjet machining

Ren¹,

Qiao²

2019

Mater. Tehnol.

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Short fiber/ceramic composites with a relatively low price and facile preparation procedure have been widely used, and waterjet is commonly used to machine hard materials because of its high efficiency. However, there is a limited number of works on the waterjet-machining behavior of ceramic incorporated with short fibers. In this study, an in-situ Cf/Al2O3 composite was prepared by in-situ transforming pre-oxidized poly-acrylonitrile fibers into carbon fibers during uni-axial hot-pressed sintering of an alumina matrix. Under the uni-axial pressure, the fibers were preferably orientated parallel to the hot-pressed surface. Pristine Al2O3 ceramic was selected to be compared with the composite. Experimental results demonstrated that the machined surface with most of its fibers being parallel to it exhibited a satisfactory machining behavior. In this situation, the average piercing depth of the composite was approximately 1.5 and 5-7 times higher than that of the Al2O3 ceramic machined with pure waterjet and abrasive waterjet, respectively. Erosion mechanisms associated with the pure-waterjet piercing of the composite were alumina-matrix intergranular or transgranular fractures and fiber spalling or fracture. For the abrasive waterjet, micro-fracture of the alumina grains and fibers together with a grain plastic deformation and abrasive micro-melting were discovered to be the dominant erosion mechanisms. It was concluded that waterjet is an effective method for piercing short fiber/ceramic composites but the piercing behavior is closely related to the fiber orientation. Keywords: ceramic-matrix composite, carbon fiber, waterjet, piercing Kompoziti s kerami~no matrico in kratkimi vlakni kot oja~itveno fazo so relativno poceni, ker jih je mo`no izdelovati z enostavnim postopkom. Rezanje oz. mehanska obdelava zelo trdih materialov se pogosto izvaja z vodnim curkom, ki je zelo u~inkovit postopek. Vendar pa je bilo do sedaj izvedeno zelo majhno {tevilo {tudij, ki obravnavajo obna{anje vodnega curka med prodiranjem skozi kerami~ne materiale v katerih se nahajajo kratka vlakna. V {tudiji so avtorji izdelali Cf/Al2O3 kompozit z in-situ pretvorbo predoksidiranih poliakrilonitrilnih vlaken v ogljikova (Cf) vlakna, med enoosnim vro~im sintranjem pod tlakom Al2O3 matrice. Pod enoosnim tlakom so se vlakna prednostno orientirala vzporedno z vro~e stiskano povr{ino. Za primerjavo z izdelanim kompozitom so izbrali izhodno Al2O3 keramiko. Eksperimentalni rezultati so pokazali, da je mehansko obdelana povr{ina z ve~ino paralelnih vlaken, ustrezna. Povpre~na globina prodiranja vodnega curka v kompozit je bila pribli`no 1,5-krat ve~ja pri uporabi~istega vodnega curka in 5-do 7-krat ve~ja pri uporabi vodnega curka z dodatkom abrazivnega sredstva, kot pri primerjalni~isti Al2O3 keramiki. Mehanizmi erozije prodiranja s~istim vodnim curkom so v kerami~ni matrici imeli zna~ilnosti inter-in trans-granularnega preloma ter drobljenja vlaken. Pri uporabi vodnega curka z dodatkom abrazivnega sredstva je pri{lo do mikro-prelomov kerami~nih zrn sk...

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CFD-aided prediction of the shape of abrasive slurry jet micro-machined channels in sintered ceramics

Cited by 43 publications

References 16 publications

Predicting Surface Roughness and Delamination When Abrasive Waterjet Machining Fiber Reinforced Polymer Composites

Predicting Surface Roughness and Delamination When Abrasive Waterjet Machining Fiber Reinforced Polymer Composites

Experimental Study on Machining Engineering Ceramics by Electrochemical Discharge Compound Grinding

Piercing behavior of an in-situ Cf/Al2O3 composite in waterjet machining

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