Effect of entrained air in abrasive water jet micro-machining: Reduction of channel width and waviness using slurry entrainment

Haghbin, Naser; Ahmadzadeh, Farbod; Spelt, J.K.; Papini, M.

doi:10.1016/j.wear.2015.10.008

Cited by 28 publications

(23 citation statements)

References 35 publications

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“…In ductile materials, reducing the nozzle angle from 90º increases the erosion rate and makes the channels deeper [69]. Also, a jet oblique incidence can affect the flow field causing a greater fraction of the flow to be directed along the channel rather than up the side walls [27]. In ductile materials this leads to a narrower channels due to a reduction in secondary slurry flow as reported by Nouraei et al [28].…”

Section: Leveling Phenomenonmentioning

confidence: 91%

“…It has also been reported that beyond a certain SOD, the central water jet breaks up into droplets, and that this length is sensitive to water jet velocity, generally falling between 50dm and 125dm, where dm is the mixing tube diameter [24]. It is found that increasing the SOD also generally results in an increase in the surface waviness because the increased jet footprint diameter reduces the energy density at the jet periphery which generates more random peaks and valleys [27].…”

Section: The Effect Of Traverse Speed On the Depth And Roughnessmentioning

confidence: 98%

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Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Azarsa¹

2023

Preprint

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Many advanced engineering materials are machined using abrasive water jets, a non-traditional machining method that has certain advantages compared to other approaches. This dissertation aims at developing methodologies to use abrasive water and slurry jets to micro-machine free-standing structures for heat sink and microfluidics applications. The first aim was to fabricate high aspect ratio free-standing structures with a minimum distance between each other that would lead to maximum heat transfer performance in heat sinks. The effect of machining process parameters on the quality of the resulting free-standing structures was studied. It was demonstrated that high-quality free-standing structures with aspect ratios of more than 40 to be used as fins in heat sinks could be fabricated. There is an increasing demand for metallic micro-molds that can be used for inexpensive mass production of polymeric microfluidic chips. Therefore, the feasibility of using abrasive water jet micro-machining (AWJM) and abrasive slurry jet micro-machining (ASJM) to fabricate such micro-molds was studied. Jet raster scans under various combinations of process parameters were used in order to machine micro-pockets containing free-standing structures, representing molds for casting microfluidic chips with channel networks. The optimum process parameters and material were determined in order to fabricate the molds with the best possible surface finish. Because unmasked machining could not be used to fabricate molds with sharp-edged intersecting features, a hybrid AWJM/ASJM masked machining technique was introduced. By careful selection of the process parameters, high quality molds with both single and intersecting free-standing structures at multiple heights could be fabricated, thus making three-dimensional microfluidic chip mold fabrication feasible. Finally, a new method of mold fabrication that utilized water jet cutting technology to cut free-standing structures out of mild steel sheets, to be used as a mold for PDMS casting, was developed. This enabled 3D features having very abrupt changes in depth with almost 90o angles for use in microfluidic devices. As a proof-of-concept, a polydimethylsiloxane (PDMS) chip was made and tested. It was shown that this alternative approach to create microfluidic molds is versatile and may find utility in reducing the cost and complexity involved in fabricating 3D features in microfluidic devices.

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Section: Leveling Phenomenonmentioning

confidence: 91%

Section: The Effect Of Traverse Speed On the Depth And Roughnessmentioning

confidence: 98%

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Azarsa¹

2023

Preprint

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“…The increase in STD losses the kinetic energy and thereby reduces the intensity of cut. This worsens the machining efficiency during the lower surface erosion because of the spreading of the concentrated jet [31]. The maximum MRR is obtained for the AFR of 2 kg/min and STD of 1.5 mm.…”

Section: Effect Of Traverse Speed Abrasive Flow Ratementioning

confidence: 95%

Experimental investigations on abrasive water jet machining of nickel-based superalloy

Veerappan¹,

Ravichandran²

2019

J Braz. Soc. Mech. Sci. Eng.

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Waspaloy is often used in aviation combustion chamber at extreme environments. Waspaloy is also a nickel-based superalloy with exceptional strength properties at a temperature of 980 °C. In this experimental investigation, waspaloy is used to analyse the kerf angle (KA), surface roughness (SR) and material removal rate (MRR) during abrasive water jet machining. The effect of various parameters such as traverse speed, abrasive flow rate, water pressure and stand-off distance on KA, MRR and SR was discussed. The striation formation was analysed for different set of process parameters. The striations were also analysed using atomic force microscopy. An attempt was done to relate the jet impinging angle and nature of striation formation. It was found that the increase in declination angle decreases the formation of striation during water jet process of waspaloy.

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“…In general, the flushing pressure and particle velocity used during the machining process have an impact on the Ra of the brittle materials machined through AWJM [28]. The distribution of abrasive particles in the AWJM is an important factor that decides roughness of the surface of the machined composite.…”

Section: Effect Of Process Parameters and Levels On Surface Roughnessmentioning

confidence: 99%

Characterization and optimization of abrasive water jet machining parameters of aluminium/silicon carbide composites

Gowthama,

Somasheker,

Suresha

et al. 2023

Mater. Res. Express

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Due to the complexity of high temperature and cutting tool wear, most machined components are still facing problems in terms of harder functional fillers that reinforce aluminium matrix composites. Conversely, abrasive water jet machining (AWJM) incredibly useful for the cutting of anisotropic and non-homogeneous metal matrix composites. In this research article, silicon carbide (SiC) particulates were utilized as reinforcement in the AA6026 matrix material (AA6026/SiC) and machined using AWJM under different process parameters namely SiC loading, traverse speed and stand-off distance. Two different compositions of SiC (4, and 8 wt%) were considered to fabricate AA6026 composites using the stir casting. In addition, outputs have been examined, e.g., surface roughness, material removal rate, and kerf angle. An optical microscope, scanning electron microscope, Brinell hardness tester and universal testing machine have been used to characterize the matrix material AA6026 and its composites. Microstructural analysis revealed that the inclusion of SiC particulates in AA6026 affects the very fine grain size of the composite. Furthermore, the 8 wt% composite exhibits the evolution of the Al-Si eutectic phase during solidification. Processing of these composites was performed using the L27 orthogonal geometry, successfully improving the parameters of the abrasive water jet process. The output response shows that reducing the SiC load improves the surface roughness under the key parameters of traverse speed and stand-off distance. However, increasing the SiC loading increases the material removal rate and kerf angle under the key parameters, namely traverse speed, and stand-off distance.

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Effect of entrained air in abrasive water jet micro-machining: Reduction of channel width and waviness using slurry entrainment

Cited by 28 publications

References 35 publications

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Fabrication of Free-Standing Structures Using Abrasive/Slurry Jet Micro-Machining

Experimental investigations on abrasive water jet machining of nickel-based superalloy

Characterization and optimization of abrasive water jet machining parameters of aluminium/silicon carbide composites

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