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Proceedings of the Fourth U.S. Water Jet Conference

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Proceedings of the Fourth U.S. Water Jet Conference PROCEEDINGS OF THE FOURTH U.S. WATER JET CONFERENCE held at THE UNIVERSITY OF CALIFORNIA, BERKELEY AUG UST 26-28, 1987 sponsored by THE WATER JET TECHNOLOGY ASSOCIATION THE MINING AND EXCAVATION RESEARCH INSTITUTE Conference Chairmen MICHAEL HOOD DAVID DORNFELD published on behalf of the Conference by THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS United Engineering Center • 345 East 47th Street • New York, N.Y. 10017 Library of Congress Catalog Number 87-71878 Permission to post to the WJTA web site granted to the WaterJet Technology Association by the publisher - The American Society of Mechanical Engineers. Please Note. This text is a scanned in version of the original. Statement from By-Laws: The Society shall not be responsible for statements or opinions advanced in papers . or printed in its publications (7.1.3) Any paper from this volume may be reproduced without written permission as long as the authors and publisher are acknowledged. Copyright © 1987 by THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS All Rights Reserved Printed in USA FOREWORD The U.S. Water Jet Conference, held every two years, provides a forum for research workers and 4 practitioners to exchange information and ideas on a variety of topics in this developing area of technology. This year, as in the past, the research work is well represented. Much of it has to do with the fast-growing field of water jets with entrained abrasives. At previous meetings practitioners have been largely representatives from the rock and concrete cutting, mining, and cleaning industries. While these industries are amply represented, this year, for the first time, emphasis also is being placed on the use of water jets in factories, reflecting the expanding applications for this technology to manufacturing industries. The papers selected for presentation at the conference represent an excellent state- of-the-art review of the many different aspects of this important and growing field. M. Hood D. Dornfeld CONTENTS FIELD APPLICATIONS—MANUFACTURING Milling With Abrasive-Waterjets: A Preliminary Investigation M. Hashish The Use of High Pressure Waterjets in Cutting Foam S. Yazici and D. A. Summers RESEARCH Percussive Jets - State-of-the-Art E. B. Nebeker Theoretical Analysis and Experimental Study of The Self-Excited Oscillation Pulsed Jet Device Liao Zheng Fang and Tang Chuan Lin Dynamic Characteristics of Waterjets Generated From Oscillating Systems W. Z.''Ben'' Wu, D. A. Summers, and M. J. Tzeng Flow Visualization of High-Speed Water Jets M. Szymczak, S. Tavoularis, A. Fahim, and M. M. Vijay Considerations in the Design of a Waterjet Device for Reclamation of Missile Casings D. A. Summers, L. J. Tyler, J. Blaine, R. D. Fossey, J. Short, and L. Craig FIELD APPLICATIONS - CONSTRUCTION Development of Cavitating Jet Equipment for Pavement Cutting A. F. Conn, M. T. Graced W. Rosenberg, and S. T. Gauthier Hydro Demolition—Technology for Productivity and Profits for America R. J. Nittinger Abrasive-Waterjet and Waterjet Techniques for Decontaminating and Decommissioning Nuclear Facilities D. C. Echert, M. Hashish, and M. Marvin RESEARCH AND DEVELOPMENT MINING Jet Kerfing Parameters for Confined Rock J.J. Kolle Conical Water Jet Drilling W. Dickinson, R. D. Wilkes, and R. W. Dickinson The Effect of Pre-Weakening a Rock Surface, by Waterjet Kerfing, on Cutting Tool Forces J. E. Geierand M. Hood RESEARCH Study of Particle Velocities in Water Driven Abrasive Jet Cutting R. K. Swanson, M. Kilman, S. Cerwin, and W. Carver Hydroabrasive Cutting Head—Energy Transfer Efficiency G. Galecki and M. Mazurkiewicz FIELD APPLICATIONS- MINING Water Jet Assisted Longwall Shearer: Development and Underground Test E. D. Thimons, K. F. Hauer, and K Neinhaus Considerations in the Use of High Speed Water Jets for Deep Slotting of Granite M. M. Vijay, J. Remiss, B. Hawrylewicz, and R. J. Puchala An Abrasive Water Jet Rock Drill G. A. Savanick and W. G. Krawza FIELD APPLICATIONS—CLEANING A Relative Cleanability Factor A. F. Conn, M. T. Graced and W. Rosenberg The Development of a High Production Abrasive Water Jet Nozzle System M. J. Woodward and R. S. Judson Cleaning the Tube Side of Heat Exchangers R. Paseman and L. Griffith Rotary Waterblast Lancing Machines G. Zink and J. Wolgamott RESEARCH AND DEVELOPMENT—MANUFACTURING Material Dynamic Response During Hydroabrasive Jet Machining (HAJM) M. Mazurkiewicz and P. Karlic Surface Finish Characterization in Machining Advanced Ceramics by Abrasive Waterjet D. C. Hunt, C. D. Burnham, and T. J. Kim Abrasive Waterjet Cutting of Metal Matrix Composites K. F. Neusen, P. K. Rohatgi, C. Vaidyanathan, and D. Alberts MILLING WITH ABRASIVE-WATERJETS: A PRELIMINARY INVESTIGATION M. Hashish, Senior Research Scientist Flow Research Company Kent, Washington ABSTRACT The feasibility of milling with abrasive waterjets has been investigated in this research. Results of milling experiments indicate that abrasive waterjets have great potential to be used as a machining tool with advantages unmatched by existing techniques. Linear cutting experiments were first conducted on sample materials (aluminum, titanium and Inconel) to generate a data matrix. Cutting results indicate a similarity of trends among these materials. Also, data were correlated against a previously developed cutting model. Although there is a strong correlation between theory and experiments, accuracy of predictions must be improved for more precise machining prediction and planning. Single-pass milling tests were conducted to observe the geometry of produced slots and the nature of surface irregularity. Multiplass milling tests were conducted on such materials as aluminum, glass, titanium and graphite composites. Surface topography was found to be a function of cutting and abrasive parameters, and surface finish was found to be strongly affected by abrasive particle size. A comparison with other machining techniques is presented in this paper. Abrasive-waterjet milling is among the most efficient methods of energy utilization for material removal. INTRODUCTION The rapid growth of harder and difficult-to-machine materials over the past two decades necessitates the development of compatible machining techniques. Conventional edge tool machining may not be technically or economically adequate for the machining of such materials. New machining techniques have been correspondingly emerging to fill the gaps where conventional methods are inefficient. These new techniques employ different physical phenomena or energy utilization to remove material. For example, mechanical, thermal, chemical and radiation energy forms (Ref. 1 - 4) constitute over 15 different techniques of nontraditional machining methods. One of the most recent machining methods is the abrasive-waterjet (AWJ) technique. Abrasive-waterjets are formed in a small abrasive-jet nozzle, as shown in Figure 1. Water is pressurized up to 400 MPa and expelled through a sapphire orifice to form a coherent, high-velocity waterjet (5). The waterjet and a stream of solid abrasives are introduced into a hard-material mixing and accelerating tube. Here, part of the waterjet's momentum is transferred to the abrasive particles, whose velocities rapidly increase. Typical particle velocities are 300-600 m/s with mass flow rates of about 10 g/s. A focused, high-velocity abrasive-waterjet exits the accelerator nozzle and performs the cutting action. Cutting or controlled depth penetration (milling) of the target material occurs as a result of complex erosion phenomena. 1 Figure 1. Abrasive-Waterjet Nozzle concept. The cutting rate can be controlled by adjusting the abrasive-waterjet parameters, which include: • Hydraulic parameters - Waterjet orifice diameter - Supply pressure • Abrasive parameters - Material (density, hardness, shape) - Size - Flow rate - Feed method (force feed or suction) - Abrasive condition (dry or slurry) • Mixing nozzle parameters - Mixing chamber dimensions - Nozzle material •Cutting parameters - Traverse rate - Number of passes - Standoff distance - Angle of cutting In this paper, a model of the AWJ cutting process is first employed to guide the milling experiments. Single-pass and multiple-pass milling experiments are then described. Finally, a comparison with another technique is presented. 2 MODEL EMPLOYMENT Three materials were used to conduct linear cutting tests: aluminum, titanium and Inconel. Hydraulic, abrasive, mixing and cutting parameters were varied to generate a data matrix on the effects of these materials on depth of cut. The main objectives of generating this data matrix are to: • Use data to verify a prediction model. • Use the prediction model, if adequate, to forecast a machining strategy. • Observe the geometrical quality of cuts. - Roughness of produced surface - Variation of depth of cut along the direction of traverse The following is a discussion of this effort: Review of Model Cutting with abrasive-waterjets has been found to consist of two modes (6,7): the cutting wear mode occurs by the impact of particles at shallow angles (8), and the deformation wear mode occurs by impacts at large angles (9,10). The first mode results in a steady-state cutting interface, while the second is unsteady. The relative contribution of each mode to the total depth of cut depends on the traverse rate. Above a critical traverse rate, the cutting will be due only to the deformation wear mode. The total depth of cut (h) can be expressed with a simplified model as m v2 2m (1 - c)v 2 h = a + a (1) 8 u u d j where V is the jet velocity, s is
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