Study on the Effect of Standoff Distance on Processing Performance of Alumina Ceramics in Two Modes of Abrasive Waterjet Turning Patterns

Abstract

Abrasive waterjet (AWJ) turning is an emerging technology, which plays an important role in machining cylindrical parts with the distinct advantages of negligible thermal effects and extremely low cutting force. This paper presents an experimental study of abrasive waterjet turning (AWJT) of Al2O3ceramics. The machining process and performance in terms of the depth of penetration (DOP), surface roughness (Ra) and actual impact angle (β) are discussed to understand the effect of standoff distance (SOD) on the processing performance at two different turning modes. Based on the results of these investigations, there is a significant change ofDOPandRaat differentSODin radial mode turning and the optimalSODof gaining maximumDOPand the minimumRais about 5.5mm.However, theDOPis nearly independent on theSODin offset mode turning. SmallerRaandDOPcan be obtained in offset mode. Furthermore, the results indicate that the roundness error of cylinder parts is probably improved with the properSODinterval in radial mode turning and it is suitable for machining cylinder part with considerably different radial size. The offset mode turning as the next operation after radial mode turning is recommended to process workpiece with excellent roundness. In this way, by understanding the effect ofSODon processing alumina ceramics, the paper establishes a good basis for developing strategies for optimizing processing parameters in order to generate the desired part geometry and achieve better surface quality.

A user-friendly finite element model for radial mode abrasive waterjet turning

“…The simulations were conducted on a desktop computer with an Intel® Core™ i7-4790K (4.4 GHz) processor and 32 GB RAM, running under a 64-bit operating system (Windows 10 Professional). The problem size was in the range between 1.6 e 6 and 2.2 e 6 degrees of freedom, and it took from 18 to 27 h on average to complete the simulation process in each run. It should be noted that the simulation step time was obtained according to following equation:…”

“…Li et al 5 pointed out that the radial mode is more efficient based on the rate of material removal since it allows the maximum utilization of the AWJ energy. Liu et al 6 were able to achieve a higher material removal rate (MRR) up to 28% using the radial mode turning of alumina ceramics at the same turning conditions. On the other hand, the offset mode can provide better surface quality and easier control of the cutting depth.…”