The linear inverse problem in energy beam processing with an application to abrasive waterjet machining

Guillerna, A. Bilbao; Axinte, Dragoş; Billingham, J.

doi:10.1016/j.ijmachtools.2015.09.006

Cited by 35 publications

(25 citation statements)

References 18 publications

(25 reference statements)

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“…The model is computationally inexpensive, taking less than 10 seconds to simulate the processing of one mm 2 surface, and accurate, less than 5% error on average; it can be used as a tool to pre-compute and optimise the beam path and also as an online prediction tool in association with inline measurement systems. It represents a significant development in pulsed laser machining and allows the development of specialised CAD/CAM software for the automatic planning and optimisation of the beam path and processing parameters as presented for abrasive waterjet machining in [36].…”

Section: Resultsmentioning

confidence: 99%

Continuous trench, pulsed laser ablation for micro-machining applications

Cadot

Axinte

Billingham

2016

International Journal of Machine Tools and Manufacture

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The generation of controlled 3D micro-features by pulsed laser ablation in various materials requires an understanding of the material's temporal and energetic response to the laser beam. The key enabler of pulsed laser ablation for micro-machining is the prediction of the removal rate of the target material, thus allowing real-life machining to be simulated mathematically.Usually, the modelling of micro-machining by pulsed laser ablation is done using a pulse-by-pulse evaluation of the surface modification, which could lead to inaccuracies when pulses overlap.To address these issues, a novel continuous evaluation of the surface modification that use trenches as a basic feature is presented in this paper. The work investigates the accuracy of this innovative continuous modelling framework for micro-machining tasks on several materials. The model is calibrated using a very limited number of trenches produced for a range of powers and feed speeds; it is then able to predict the change in topography with a size comparable to the laser beam spot that arises from essentially arbitrary toolpaths. The validity of the model has been proven by being able to predict the surface obtained from single trenches with constant feed speed, single 1 trenches with variable feed speed and overlapped trenches with constant feed speed for three different materials (graphite, polycrystalline diamond and a metal-matrix diamond CMX850) with low error. For the three materials tested, it is found that the average error in the model prediction for a single trench at constant feed speed is lower than 5 % and for overlapped trenches the error is always lower than 10 %. This innovative modelling framework opens avenues to: (i) generate in a repeatable and predictable manner any desired workpiece micro-topography; (ii) understand the pulsed laser ablation machining process, in respect of the geometry of the trench produced, therefore improving the geometry of the resulting parts; (iii) enable numerical optimisation for the beam path, thus supporting the development of accurate and flexible computer assisted machining software for pulsed laser ablation micro-machining applications.

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Section: Resultsmentioning

confidence: 99%

Continuous trench, pulsed laser ablation for micro-machining applications

Cadot

Axinte

Billingham

2016

International Journal of Machine Tools and Manufacture

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“…It has been found that, for shallow trenches (i.e. large feed speeds), a linear model can be used to predict the average trench profile [22], and therefore the problem can be stated as…”

Section: Stochastic Modelling Of Abrasive Waterjet Millingmentioning

confidence: 99%

Stochastic simplified modelling of abrasive waterjet footprints

2016

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Abrasive micro-waterjet processing is a nonconventional machining method that can be used to manufacture complex shapes in difficult-to-cut materials. Predicting the effect of the jet on the surface for a given set of machine parameters is a key element of controlling the process. However, the noise of the process is significant, making it difficult to design reliable jet-path strategies that produce good quality parts via controlled-depth milling. The process is highly unstable and has a strong random component that can affect the quality of the workpiece, especially in the case of controlled-depth milling. This study describes a method to predict the variability of the jet footprint for different jet feed speeds. A stochastic partial differential equation is used to describe the etched surface as the jet is moved over it, assuming that the erosion process can be divided into two main components: a deterministic part that corresponds to the average erosion of the jet and a stochastic part that accounts for the noise generated at different stages of the process. The model predicts the variability of the trench profiles to within less than 8%. These advances could enable abrasive micro-waterjet technology to be a suitable technology for controlled-depth milling.

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“…This is preferable to an ordinary jet sample on the material effect through the positive impact of broken rock. So rotating conical abrasive jet pressure on the material radial is in the form of an "extend" force and a circular "cut" force, plus the positive impact force, and it will be easy to meet or exceed the corresponding strength of the materials, which produces material destruction through stretch and shear, greatly improving the crushing efficiency [17] [18].…”

Section: Track Equation Of the Rotating Water Jetmentioning

confidence: 99%

The Research of Stress Theoretical Analysis and Structural Parameters of Sprayer Fluid of Rotating Conical Abrasive Jet

Li¹,

Ge²,

Zheng³

et al. 2015

IJHT

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The characteristics of a jet flow are analyzed. A rotating cone water jet is formed by using plus adding a special spiral section on the basis of research at home and abroad. According to the structural characteristics of the spiral groove, combined with the characteristics of the nozzle and requirements, a spin and nozzle structure is designed which has a spiral groove with certain parameters. A rotating conical water jet is thereby obtained. The force is analyzed in a high pressure pipe and fluid while spinning, and these are analyzed for the contraction in the force of the abrasive particles and the force of the fluid leaving the jet nozzle. The movement characteristics of the particles are understood as fluid in the jet formation process, which provides data support for further study for adding abrasive particles. A trajectory equation of the rotating cone water jet is derived based on the characteristics of the fluid movement, focusing on the actual movement of the fluid. The movement characteristics and mechanical properties of the fluid in a nozzle are also analyzed. The influence of nozzle structure parameters on the formation of the jet is obtained through experimental study. This shows that the cross section of the ring or circle diameter D correspondingly decreases with the increase of pitch H, and the inner diameter D essentially remains unchanged. The section shape of the basis is a circle with a center hole with a diameter of 2 mm. The brightness of the section with the hole is inferior to the condition of the one without a hole. The increasing trend of circle diameter D is more than that of the inner diameter D as the nozzle diameter di increases. These are the theoretical and experimental foundations for further optimizing spinning structures.

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The linear inverse problem in energy beam processing with an application to abrasive waterjet machining

Cited by 35 publications

References 18 publications

Continuous trench, pulsed laser ablation for micro-machining applications

Continuous trench, pulsed laser ablation for micro-machining applications

Stochastic simplified modelling of abrasive waterjet footprints

The Research of Stress Theoretical Analysis and Structural Parameters of Sprayer Fluid of Rotating Conical Abrasive Jet

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