Numerical simulation of surface roughness and erosion rate of abrasive jet micro-machined channels

Jafar, R. Haj Mohammad; Spelt, J.K.; Papini, M.

doi:10.1016/j.wear.2013.03.021

Cited by 46 publications

(8 citation statements)

References 22 publications

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“…To avoid this, an alternate technique for superimposing profiles was utilized which allowed peaks to be eroded, but valleys to be preserved unless directly exposed to an impact. The technique is analogous to that used by Jafar et al [56] in the simulation of the smoothing of glass surfaces due to the edge chipping of peaks when impacted by particles at oblique incidence.…”

Section: Methods To Superimpose Multiple Profiles (Block C)mentioning

confidence: 99%

“…Several authors have developed process models for predicting surface roughness when using abrasive jets to machine brittle materials such as glass. For example, Jafar et al [56] developed a numerical model for air abrasive jet machining (AJM) of micro-channels in borosilicate glass as a function of particle size, velocity, dose, impact angle and target material properties. The model simulated brittle erosion using two damage mechanisms: crater removal due to lateral crack formation and edge chipping.…”

Section: Introductionmentioning

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: Methods To Superimpose Multiple Profiles (Block C)mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

Schwartzentruber¹

2023

Preprint

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“…The meshing process was performed on the models with 10-node quadratic tetrahedral elements and the mesh size was set to 0.001 mm. According to the published data by Jafar et al [24], the impact velocity of single abrasive particle can be estimated (Figure 3). The incident velocity of the impact particle was calculated by Equation (2):…”

Section: D-finite Element Analysis (Fea)mentioning

confidence: 99%

Phase Transformations and Subsurface Changes in Three Dental Zirconia Grades after Sandblasting with Various Al2O3 Particle Sizes

et al. 2021

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Although sandblasting is mainly used to improve bonding between dental zirconia and resin cement, the details on the in-depth damages are limited. The aim of this study was to evaluate phase transformations and subsurface changes after sandblasting in three different dental zirconia (3, 4, and 5 mol% yttria-stabilized zirconia; 3Y-TZP, 4Y-PSZ, and 5Y-PSZ). Zirconia specimens (14.0 × 14.0 × 1.0 mm3) were sandblasted using different alumina particle sizes (25, 50, 90, 110, and 125 µm) under 0.2 MPa for 10 s/cm2. Phase transformations and residual stresses were investigated using X-ray diffraction and the Williamson-Hall method. Subsurface damages were evaluated with cross-sections by a focused ion beam. Stress field during sandblasting was simulated by the finite element method. The subsurface changes after sandblasting were the emergence of a rhombohedral phase, micro/macro cracks, and compressive/tensile stresses depending on the interactions between blasting particles and zirconia substrates. 3Y-TZP blasted with 110-µm particles induced the deepest transformed layer with the largest compressive stress. The cracks propagated parallel to the surface with larger particles, being located up to 4.5 µm under the surface in 4Y- or 5Y-PSZ subgroups. The recommended sandblasting particles were 110 µm for 3Y-TZP and 50 µm for 4Y-PSZ or 5Y-PSZ for compressive stress-induced phase transformations without significant subsurface damages.

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“…Haj Mohammad Jafar et al [44] developed a numerical model that predicted the roughness as well as the erosion rate of a brittle material subjected to unmasked AJM process. The study concluded that by decreasing the angle of attack, the number of edge chipping increased; however, the major damage mechanism was caused by crater removal at both normal and shallow impact angles.…”

Section: Brittle Erosionmentioning

confidence: 99%

Effect of curing parameters and configuration on the efficacy of ultraviolet light curing self-adhesive masks used for abrasive jet micro-machining and microfluidic device fabrication

Ahmadzadeh¹

2021

Preprint

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Soft lithography techniques has been used widely in the past decade to fabricate microfluidic chips used in biomedical applications. Abrasive jet machining (AJM) has been used to fabricate similar chips using particle erosion mechanisms. This thesis proposes a new technique using a UV light sensitive self-adhesive mask (RapidMask) and AJM to fabricate a three dimensional flow focusing microfluidic chip where the depth of the channel is allowed to vary along the channel length. A detailed characterization of the effect of curing parameters of a UV light curing self-adhesive mask on the resulting feature resolution is reported. Instead of relying on the manufacturer recommended curing parameters which were vaguely described for specific UV curing units, it was found that measured energy density could be used to quantify a recommended cure that is independent of the curing unit. The best achievable pattern on borosilicate glass using RM and AJM was found and reported along with the erosion rates of uncured, cured RM during AJM. A new methodology was introduced to use multiple layers of the RM in order to increase the achievable feature aspect ratio. The results of the RM curing and multiple layer investigation were then used to fabricate a three dimensional flow focusing chip with a varying depth at the focusing junction. The chip was then sealed and tested to demonstrate its capabilities and potential in healthcare and biomedical applications. To the best knowledge of the author, this thesis is the first to report using a double layer RM to fabricate a microfluidic chip using AJM.

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Numerical simulation of surface roughness and erosion rate of abrasive jet micro-machined channels

Cited by 46 publications

References 22 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

Phase Transformations and Subsurface Changes in Three Dental Zirconia Grades after Sandblasting with Various Al2O3 Particle Sizes

Effect of curing parameters and configuration on the efficacy of ultraviolet light curing self-adhesive masks used for abrasive jet micro-machining and microfluidic device fabrication

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