Quality of Hydroabrasive Waterjet Cutting Machinability 2

Home , Chisel

Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect Available online at www.sciencedirect.com ScienceDirect 2 G. Barsukov, T. Zhuravleva, O. Kozhus / Procedia Engineering 00 (2017) 000–000 Procedia Engineering 00 (2017)000–000 Procedia Engineering 00 (2017)000–000 www.elsevier.com/locate/procedia ScienceDirect Operational experience has demonstrated that the main problem of laminated material hydroabrasive cutting is a www.elsevier.com/locate/procedia lamination occurrence during initial material drifting. Experiments have shown that the appearance and lamination Procedia Engineering 206 (2017) 1034–1038 value are influenced both by technological parameters of drifting (focussing tube trajectory and diameter, drifting pressure, abrasive grain average size) and physical and mechanical material properties and its condition while processing (material microcracks, micropores, microdefects that emerged during manufacture, transportation and

International Conference on Industrial Engineering, ICIE 2017 storage) [11-17]. This type of factors belongs to "uncontrolled" group since each plate stock has a unique set of International Conference on Industrial Engineering, ICIE 2017 micropores, microcracks, microdefects, allowed by the GOST 12652-74 requirements. Quality of Hydroabrasive Waterjet Cutting Machinability 2. Development of machinability criteria Quality of Hydroabrasive Waterjet Cutting Machinability G. Barsukov, T. Zhuravleva, O. Kozhus* It is proposed to carry out laminated material machinability assessment using the relative machinability index on

G. Barsukov, T. Zhuravleva, O. Kozhus* the basis of lamination value (lamination machinability index) KH. Orel State University, 95, Komsomolskaya street, Orel 302026, Russia Lamination machinability index is the ratio of the processed material lamination value H and the reference Orel State University, 95, Komsomolskaya street, Orel 302026, Russia material lamination value at optimal technological mode experimentally obtained for given thickness HR:

Abstract H KH  (1) Abstract H R The article suggests a criterion of plate laminated material machinability depending on the separation by hydroabrasive waterjet is used at initial drifting. The criterion allows determining the necessity of the technological drifting mode adjustment. Also they The article suggests a criterion of plate laminated material machinability depending on the separation by hydroabrasive waterjet where H - lamination value of processed material, mm; H – lamination value of reference material at optimal isallow used assessing at initial thedrifting. necessity The criterionof inter-pattern allows distancedetermining increase the necessity while details of the marking, technological the necessity drifting of mode moving adjustment. the initial Also dri ftingthey R technological mode, mm. allowpoint awayassessing from the processing necessity ofcontour, inter-pattern the ne cessitydistance of increase using specialwhile details technological marking, m theodes necessity ("clipping of movingcut", etc.) the ininitial the dricut-outfting pointdetails, away the frompossibility processing of the contour, internal the surfaces necessity (axial of usingslots, specialmortises, technological apertures, metc.)odes processing. ("clipping Acut", technique etc.) in ofthe materialcut-out The higher value lamination machinability index KH is, the more distinction between properties of standard and details,diagnostics the andpossibility determination of the internalof a relative surfaces lamination (axial slots,machinability mortises, indexapertures, for sheetetc.) layeredprocessing. glass A plastics technique fiber of hasmaterial been processed material it shows. diagnosticsdeveloped. Theand diagnosticsdetermination algorithm of a relative for gla sslamination plastic fiber machinability and the determination index for ofsheet relative layered lamination glass plastics machinability fiber has index been is In the absence of lamination the lamination value is taken as Н = 1 which is commensurable with diameter of hole developed. The diagnostics algorithm for glass plastic fiber and the determination of relative lamination machinability index is formed in the material while drifting. © 2017 The Authors. Published by Elsevier B.V. developed.© 2017 The Authors. Published by Elsevier Ltd. Quantitative assessment of laminated materials machinability, for instance, glass-cloth-base laminate, is an Peer-review© 2017 The Authors.under responsibility Published by of Elsevierthe scientific B.V. committee of the International Conference on Industrial Engineering. extremely important characteristic which allows specialist to make stock layout in order to solve the following Keywords:Peer-review abrasive under waterjet; responsibility machinability of the crite scientificrion; machinability; committee laminatedof the International materials; cutting Conference of many on details; Industrial hole drilling. Engineering Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering. problems: Keywords: abrasive waterjet; machinability criterion; machinability; laminated materials; cutting of many details; hole drilling. 1. Determine the need of technological drifting mode adjustment. 1. Introduction 2. Determine the necessity to increase an inter-pattern distance while details marking. Inter-pattern distance for the cutting is 6-8 mm for majority of materials. This value provides the absence of 1. Introduction Introduction of new manufacturing technologies as well as the enhancement of existing cutting types requires the overcuts on the details emerging from driftings and chisel edges, the rigidity of detail position during processing (absence of vibrations), safe and easy removing the details after cutting. At fiberglass processing, appearing of machinabilityIntroduction evaluation. of new manufacturing This technological technologies material as properwell asty the material enhancement determines of existing whether cutting it is possible types requires to achieve the lamination during drifting is not excluded. In order to exclude spread of lamination on the processing details, inter- machinabilityspecific technical evaluation. and technological This technological requirements material with properminimumty material cost and determines necessary whetherproduction it is efficiency possible to[1,2]. achieve pattern distance has to be larger than the lamination value by 50–60 %. Herewith, lamination remains in waste specificCutting technical machinability and technological of materials requirements can be estimated with minimum with onecost andor several necessary indices. production These efficiency include quality[1,2]. of material, and received details are considered as useful. However, the lamination sizes are larger than 10-12 mm, processedCutting surface, machinability cutting toolof materials durability, can forces be emergingestimated whilewith cutting,one or cuttingseveral speed,indices. swarf These type, include etc. quality of inter-pattern distance value should be no less than 15 mm. This pattern cutting becomes irrational in terms of processedSet of surface,criteria iscutting proposed tool duraas bility,a quantitative forces emerging estimation while for cutting, plastic cuttingcutting speed, machinability. swarf type, These etc. include the material consumption. In this case, it is necessary to use special technological actions to limit lamination spread on criterionSet of of criteria cutting isspeed proposed machinability as a quantitative estimation, estimation the criterion for of plasticcutting cuttingtool durability machinability. estimation, These etc. include[3-10]. the the detail’s surface in order to save material consumption. criterion of cutting speed machinability estimation, the criterion of cutting tool durability estimation, etc. [3-10]. 3. Determine the necessity of distance h between the point of drifting and processing contour increase, see Fig. 1. The value of this length affects the value of inter-pattern distance and therefore the economy of material consumption.

4. Determine the possibility of internal detail surfaces processing (mortises, apertures, etc.) of given material. In * Corresponding author. Tel.: +7-910-266-8598; fax: +7-486-241-3295. E-mail address: [email protected] some cases, it is preferable to process only the external contour of detail and sufficiently big penetrating * Corresponding author. Tel.: +7-910-266-8598; fax: +7-486-241-3295. elements (from 10-15 mm), and operation of remaining internal contours perform by the methods of E-mail address: [email protected] 1877-7058 © 2017 The Authors. Published by Elsevier B.V. mechanical processing. Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering . 1877-7058 © 2017 The Authors. Published by Elsevier B.V. In order to save the material, the authors propose to distinguish a sheet material from glass-cloth-base laminate Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering . into groups by the value of the index of lamination machinability:  the first group includes sheet material with an index value of lamination machinability KH≤5. Processing material is regarded as standard in its properties;  ≤ 1877-7058 © 2017 The Authors. Published by Elsevier Ltd. the second group includes sheet material with an index value of lamination machinability 5

10.1016/j.proeng.2017.10.590 1877-7058 Available online at www.sciencedirect.com Available online at www.sciencedirect.com ScienceDirect G. Barsukov et al. / Procedia Engineering 206 (2017) 1034–1038 1035 ScienceDirect 2 G. Barsukov, T. Zhuravleva, O. Kozhus / Procedia Engineering 00 (2017) 000–000 Procedia Engineering 00 (2017)000–000 Procedia Engineering 00 (2017)000–000 www.elsevier.com/locate/procedia Operational experience has demonstrated that the main problem of laminated material hydroabrasive cutting is a www.elsevier.com/locate/procedia lamination occurrence during initial material drifting. Experiments have shown that the appearance and lamination value are influenced both by technological parameters of drifting (focussing tube trajectory and diameter, drifting pressure, abrasive grain average size) and physical and mechanical material properties and its condition while processing (material microcracks, micropores, microdefects that emerged during manufacture, transportation and

Abstract H KH  (1) Abstract H R The article suggests a criterion of plate laminated material machinability depending on the separation by hydroabrasive waterjet is used at initial drifting. The criterion allows determining the necessity of the technological drifting mode adjustment. Also they The article suggests a criterion of plate laminated material machinability depending on the separation by hydroabrasive waterjet where H - lamination value of processed material, mm; H – lamination value of reference material at optimal isallow used assessing at initial thedrifting. necessity The criterionof inter-pattern allows distancedetermining increase the necessity while details of the marking, technological the necessity drifting of mode moving adjustment. the initial Also dri ftingthey R technological mode, mm. allowpoint awayassessing from the processing necessity ofcontour, inter-pattern the ne cessitydistance of increase using specialwhile details technological marking, m theodes necessity ("clipping of movingcut", etc.) the ininitial the dricut-outfting pointdetails, away the frompossibility processing of the contour, internal the surfaces necessity (axial of usingslots, specialmortises, technological apertures, metc.)odes processing. ("clipping Acut", technique etc.) in ofthe materialcut-out The higher value lamination machinability index KH is, the more distinction between properties of standard and details,diagnostics the andpossibility determination of the internalof a relative surfaces lamination (axial slots,machinability mortises, indexapertures, for sheetetc.) layeredprocessing. glass A plastics technique fiber of hasmaterial been processed material it shows. diagnosticsdeveloped. Theand diagnosticsdetermination algorithm of a relative for gla sslamination plastic fiber machinability and the determination index for ofsheet relative layered lamination glass plastics machinability fiber has index been is In the absence of lamination the lamination value is taken as Н = 1 which is commensurable with diameter of hole developed. The diagnostics algorithm for glass plastic fiber and the determination of relative lamination machinability index is formed in the material while drifting. developed.© 2017 The Authors. Published by Elsevier B.V. Quantitative assessment of laminated materials machinability, for instance, glass-cloth-base laminate, is an ©Peer-review 2017 The Authors.under responsibility Published by of Elsevierthe scientific B.V. committee of the International Conference on Industrial Engineering. extremely important characteristic which allows specialist to make stock layout in order to solve the following Keywords: abrasive waterjet; machinability criterion; machinability; laminated materials; cutting of many details; hole drilling. Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering. problems: Keywords: abrasive waterjet; machinability criterion; machinability; laminated materials; cutting of many details; hole drilling. 1. Determine the need of technological drifting mode adjustment. 1. Introduction 2. Determine the necessity to increase an inter-pattern distance while details marking. Inter-pattern distance for the cutting is 6-8 mm for majority of materials. This value provides the absence of 1. Introduction Introduction of new manufacturing technologies as well as the enhancement of existing cutting types requires the overcuts on the details emerging from driftings and chisel edges, the rigidity of detail position during processing (absence of vibrations), safe and easy removing the details after cutting. At fiberglass processing, appearing of machinabilityIntroduction evaluation. of new manufacturing This technological technologies material as properwell asty the material enhancement determines of existing whether cutting it is possible types requires to achieve the lamination during drifting is not excluded. In order to exclude spread of lamination on the processing details, inter- machinabilityspecific technical evaluation. and technological This technological requirements material with properminimumty material cost and determines necessary whetherproduction it is efficiency possible to[1,2]. achieve pattern distance has to be larger than the lamination value by 50–60 %. Herewith, lamination remains in waste specificCutting technical machinability and technological of materials requirements can be estimated with minimum with onecost andor several necessary indices. production These efficiency include quality[1,2]. of material, and received details are considered as useful. However, the lamination sizes are larger than 10-12 mm, processedCutting surface, machinability cutting toolof materials durability, can forces be emergingestimated whilewith cutting,one or cuttingseveral speed,indices. swarf These type, include etc. quality of inter-pattern distance value should be no less than 15 mm. This pattern cutting becomes irrational in terms of processedSet of surface,criteria iscutting proposed tool duraas bility,a quantitative forces emerging estimation while for cutting, plastic cuttingcutting speed, machinability. swarf type, These etc. include the material consumption. In this case, it is necessary to use special technological actions to limit lamination spread on criterionSet of of criteria cutting isspeed proposed machinability as a quantitative estimation, estimation the criterion for of plasticcutting cuttingtool durability machinability. estimation, These etc. include[3-10]. the the detail’s surface in order to save material consumption. criterion of cutting speed machinability estimation, the criterion of cutting tool durability estimation, etc. [3-10]. 3. Determine the necessity of distance h between the point of drifting and processing contour increase, see Fig. 1. The value of this length affects the value of inter-pattern distance and therefore the economy of material consumption.

4. Determine the possibility of internal detail surfaces processing (mortises, apertures, etc.) of given material. In * Corresponding author. Tel.: +7-910-266-8598; fax: +7-486-241-3295. E-mail address: [email protected] some cases, it is preferable to process only the external contour of detail and sufficiently big penetrating * Corresponding author. Tel.: +7-910-266-8598; fax: +7-486-241-3295. elements (from 10-15 mm), and operation of remaining internal contours perform by the methods of E-mail address: [email protected] 1877-7058 © 2017 The Authors. Published by Elsevier B.V. mechanical processing. Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering . 1877-7058 © 2017 The Authors. Published by Elsevier B.V. In order to save the material, the authors propose to distinguish a sheet material from glass-cloth-base laminate Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering . into groups by the value of the index of lamination machinability:  the first group includes sheet material with an index value of lamination machinability KH≤5. Processing material is regarded as standard in its properties;  the second group includes sheet material with an index value of lamination machinability 5

To avoid the waste appearance at processing of given materials it is necessary to adjust the reference modes of drifting:  pressure reduction at drifting;  increasing the diameter of focussing tube;  using the grain material with smaller abrasive grain sizes. In some cases a need for increasing the inter-pattern distance in cutting arises.  the third group includes sheet material with an index value of lamination machinability KH>10. Under given conditions, it is necessary to adjust the technological mode of drifting as well as to perform special actions for excluding spread of lamination on the processing contour. It should be noted that the classification is particularly appropriate for external contours processing. It is necessary to match the sizes of lamination and internal contour to determine the internal contours processing advisability.

Fig. 1. Entry of hydroabrasive waterjet to processed detail contour (a) general view; (b) scaled up.

3. Determination of relative lamination machinability index

Technique for material diagnostic and determining relative lamination machinability index of laminated sheet fiberglasses using hydroabrasive cutting method was developed to provide objective assessment of the laminated materials machinability with fiberglass as an example. Material diagnostics should be executed directly before its processing. Since each plate stock is "unique" by its own physical and mechanical properties, it is necessary to perform the diagnostics for each plate stock. On the basis of giving technique, it is possible to describe the following algorithm of diagnostics sequence of actions for determining the relative lamination machinability index for fiberglass: 1. Primary control program of nesting is prepared before material diagnosis. The program includes not only the contours of details to be processed, but also several driftings at different points of plate stock. Test driftings are executed first; it is sufficient to make 8-10 test driftings. Drifting should be made at the locations of future waste of material (between the details, in the apertures or openings). Sample layout of drifting points is shown in the Fig. 2. Technological mode of drifting is allocated in compliance with the standard (Table 1).  if the material belongs to the second group (relative lamination machinability index 510), physical and mechanical properties of processing and standard material differ significantly. If the technological mode of drifting adjustment does not result in an essential reduction of lamination value, it is necessary to make special technological actions to exclude spreading the lamination on the detail surface, such as described below. G. Barsukov et al. / Procedia Engineering 206 (2017) 1034–1038 1037 G. Barsukov, T. Zhuravleva, O. Kozhus / Procedia Engineering 00 (2017) 000–000 3 4 G. Barsukov, T. Zhuravleva, O. Kozhus / Procedia Engineering 00 (2017) 000–000

Fig. 1. Entry of hydroabrasive waterjet to processed detail contour (a) general view; (b) scaled up.

3. Determination of relative lamination machinability index Fig. 2. Example of test driftings location in material diagnostics of lamination machinability.

Technique for material diagnostic and determining relative lamination machinability index of laminated sheet Table 1. Standard mode of drifting for glass-cloth-base laminate STJEF-I 1S GOST 12652-74. fiberglasses using hydroabrasive cutting method was developed to provide objective assessment of the laminated The trajectory of The critical The recommended Diameter of Used Value of reference materials machinability with fiberglass as an example. focussing tube at pressure of drifting, pressure of drifting, focussing tube, abrasive separation НR, mm Material diagnostics should be executed directly before its processing. Since each plate stock is "unique" by its drifting MPa MPa mm material Material thickness, mm own physical and mechanical properties, it is necessary to perform the diagnostics for each plate stock. 1 62 78

On the basis of giving technique, it is possible to describe the following algorithm of diagnostics sequence of 5 62 78 actions for determining the relative lamination machinability index for fiberglass: 10 64 76

1. Primary control program of nesting is prepared before material diagnosis. The program includes not only the Ø1 mm 15 66 76 Garnet contours of details to be processed, but also several driftings at different points of plate stock. Test driftings are 1 0,76 executed first; it is sufficient to make 8-10 test driftings. Drifting should be made at the locations of future waste of 20 66 76 80 mesh material (between the details, in the apertures or openings). Sample layout of drifting points is shown in the Fig. 2. 30 68 72

Technological mode of drifting is allocated in compliance with the standard (Table 1). 40 circle a in tube 68 70

≤ focussing of With a motion  if the material belongs to the second group (relative lamination machinability index 5

 if the lot of material belongs to the third group (KH>10), physical and mechanical properties of processing and fixed With

30 tube focussing 4 68 70 standard material differ significantly. If the technological mode of drifting adjustment does not result in an 40 3 68 70 essential reduction of lamination value, it is necessary to make special technological actions to exclude spreading the lamination on the detail surface, such as described below. 50 5 68 70 1038 G. Barsukov et al. / Procedia Engineering 206 (2017) 1034–1038 G. Barsukov, T. Zhuravleva, O. Kozhus / Procedia Engineering 00 (2017) 000–000 5

 if the material belongs to the second group (relative lamination machinability index 510), physical and mechanical properties of processing and standard material differ significantly. If the technological mode of drifting adjustment does not result in an essential reduction of lamination value, it is necessary to make special technological actions to exclude spreading the lamination on the detail surface, such as described below.

4. Conclusion

The technique of assessment of laminated material hydroabrasive waterjet machinability using the relative lamination machinability K_H is developed. This allows to make an adjustment of cutting to avoid lamination occurrence on the surface of finished detail. It is suggested to divide the laminated material into the groups by the value of K_H. Sheet material which does not require drifting adjustment and focussing tube trajectory adjustment belongs to the first group. Sheet material, which processing requires standard drifting modes adjustment and increasing the inter- pattern distances, belongs to the second group. Third group includes sheet material, which processing requires special actions for spreading lamination excluding on the processing countour.

References

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