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WJTA-IMCA 2013 - UHP and Cutting Applications

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  • 1. WJTA Short Course ® M. Hashish 1 UHP and Abrasive Cutting Applications Short Course By Mohamed Hashish Flow International Corporation Mhashish@flowcorp.com September 2013
  • 2. Waterjet System WJTA Short Course ® M. Hashish 2
  • 3. Water is Compressible WJTA Short Course ® M. Hashish 3
  • 4. Intensifier WJTA Short Course ® M. Hashish 4
  • 5. WJTA Short Course ® M. Hashish 5 Video
  • 6. Crosshead bushingPlunger seal Plunger Check Valve Assembly High Pressure Cylinder Crank case Direct Drive Pump WJTA Short Course ® M. Hashish 6
  • 7. Actuato r Seal Valve Orifice (Seat) Inlet Valve Stem (Poppet) Outlet Pneumatic Actuator On/Off Valve WJTA Short Course ® M. Hashish 7
  • 8. UHP Fittings & Tubing WJTA Short Course ® M. Hashish 8 Anti Vibe Thread Manual on/off Valve Various fittings
  • 9. Pressure Loss WJTA Short Course ® M. Hashish 9
  • 10. WJTA Short Course ® M. Hashish 10 /2PVth  thvVcV  dn cPdKq 2 1 dn cPdKE 5.12 2 Basic Relations • Theoretical Waterjet velocity • Actual Waterjet Velocity • Water Flow Rate • Jet power ft/sec= 12.2 Psi cv = 0.98
  • 11. WJTA Short Course ® M. Hashish 11 Hydraulic Relationships
  • 12. Hydraulic Relationships WJTA Short Course ® M. Hashish 12
  • 13. WJTA Short Course ® M. Hashish 13 Easy Unit Conversions • 1 Ksi= 6.9 MPa – So, 50,000 psi is 50 * 6.9 = 345 MPa • 1 mm = 40 thou – So, 0.5 mm = 0.020 inch • 1 thou = 25 microns – So, 0.002 inch = 50 microns
  • 14. Orifice WJTA Short Course ® M. Hashish 14
  • 15. Waterjet Coherency WJTA Short Course ® M. Hashish 15
  • 16. WJTA Short Course ® M. Hashish 16 Types of Jets Droplet Jet Cryogenic Jet Ice Jet Hybrid Jet Pulsed jet Waterjet (WJ) Fan Jet (FJ) Abrasive Waterjet (AWJ) Abrasive Suspension Jet (ASJ) Emerging Water Only Water +Abrasives Other
  • 17. Front viewSide view Orifice shape Nozzle Fanjets WJTA Short Course ® M. Hashish 17
  • 18. From Pump Nozzle Abrasives Abrasiv e Slurry Jet TO DRAIN UHP WATER FROM PUMP CHECK VALVES NOZZLE ABRASIVE SLURRY JET WATER OPEN CLOSED OPEN CLOSED ABRASIVE SLURRY IN ABRASIVE SLURRYISOLATOR MH006B a- Fluidized bed b- Isolator Abrasive Slurry (Suspension) Jets WJTA Short Course ® M. Hashish 18
  • 19. Abrasive Waterjet WJTA Short Course ® M. Hashish 19
  • 20. Air Flow in AWJ WJTA Short Course ® M. Hashish 20
  • 21. General AWJ Cutting Trends WJTA Short Course ® M. Hashish 21
  • 22. 0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 200 250 300 350 400 450 500 550 Pressure (MPa) CuttingSpeed(mm/s) dn=0.23 mm, dm= 0.79 mm, ma= 3.8 g/s 12.5-mm thick Steel 51-mm thick Aluminum Example AWJ Cutting Trend WJTA Short Course ® M. Hashish 22
  • 23. WJTA Short Course ® M. Hashish 23 Taper Divergent ConvergentStraight Speed Divergent ConvergentStraight Speed 0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 -0.08 -0.06 -0.04 -0.02 0 0.02 0.04 0.06 0.08 Width of Cut (inch) Depth(inch) Top Surface % Speed 1% 5% 10% 20% 30% 40% 50% 60% Titanium 6Al-4V p= 54 Ksi dn=0.018 inch dm= 0.060 inch lm= 4.0 inch ma= 2.1 lb/min Garnet Mesh 50 sod=0.1 inch 100% speed = 11 inch/min
  • 24. WJTA Short Course ® M. Hashish 24 Trail Back
  • 25. WJTA Short Course ® M. Hashish 25 Bottom of the Cut Cutting Speed
  • 26. Taper Control Wrists WJTA Short Course ® M. Hashish 26 Video
  • 27. - 5 10 15 20 0% 20% 40% 60% 80% 100% 120% 140% 160% 180% Cutting Speed Finish,Taper,andTrailback - 1 2 3 4 5 6 7 8 Finish Taper Trailback dominant striations speed range u 3 maximum taper speed u 1 zero taper speed u 4 maximum cut-through speed u 2 striations start speed laterally stretched image to highlight striations t Benefit of Taper Control WJTA Short Course ® M. Hashish 27
  • 28. Motion Systems WJTA Short Course ® M. Hashish 28
  • 29. WJTA Short Course ® M. Hashish 29 Large Systems
  • 30. Large Systems WJTA Short Course ® M. Hashish 30
  • 31. WJTA Short Course ® M. Hashish 31 Robotic Waterjet Trimming
  • 32. WJTA Short Course ® M. Hashish 32 Machining Processes Cutting Trimming, Slitting, Shape cutting Drilling (piercing) Small holes, Turning Diameter turning, Slicing Milling Area milling, Grooving Surface modification Texturing, Coating removal, Paint removal, Peening, .. Other Deburring, Powder fabrication, Jet assisted machining,…
  • 33. WJTA Short Course ® M. Hashish 33 AWJ Trimming of Boeing 777&7E7 Composites
  • 34. WJTA Short Course ® M. Hashish 34 Inlay Shape Cutting • Standard application • Good edge quality • Automatic cutter compensation • Special piercing strategy
  • 35. WJTA Short Course ® M. Hashish 35 Glass - Thin Web Cutting • Thin web ~ 0.01/inch • Webs may be hour glass shape • Strut vibration • Cut-out handling • Piercing Glass Core 1.5-inch thick with 0.020-inch webs
  • 36. WJTA Short Course ® M. Hashish 36 Electronics - Thin Kerf Cutting (Dicing – Singulation) AWJ • Kerf width – Minimum ~ 0.5 mm – possible ~ 0.38 inch – Future ~ 0.1 mm • Process Cpk >1.3 can be met with AWJ • ASJ is a future process for kerf width < 0.25- mm
  • 37. WJTA Short Course ® M. Hashish 37 • 300-mm Steel and Titanium • 600mm GLASS AND Aluminum • Wall straightness within 0.5-mm • Special nozzle, High power Thick Materials
  • 38. AWJ Drilling WJTA Short Course ® M. Hashish 38
  • 39. Example Rapid Drilling WJTA Short Course ® M. Hashish 39
  • 40. AWJ Milling WJTA Short Course ® M. Hashish 40
  • 41. AWJ Turning WJTA Short Course ® M. Hashish 41
  • 42. 3D Cutting and Shaping WJTA Short Course ® M. Hashish 42
  • 43. WJTA Short Course ® M. Hashish 43 Waterjet Peening Compressive residual stress depth depth Work hardening HV Water droplet _ + Surface roughness & erosion of material 
  • 44. WJTA Short Course ® M. Hashish 44 Ceramic Coat Stripping
  • 45. WJTA Short Course ® M. Hashish 45 Surface Roughening
  • 46. WJTA Short Course ® M. Hashish 46 References • Hashish, “The Waterjet as a Tool,” Proceedings of the 14th International Water Jet Cutting Technology Conference, BHR group, Brugge, Belgium, October 1998. • Knaupp, M., et. Al., “Dynamic Compensation of Abrasive Waterjet Properties through 3-Dimensional Jet Control,” Proceedings of the 16th International Conference on Jet Cutting Technology, Aix-en-Provenece, France, P. Lake, ed., BHR Group Conference Series, October 2002, pp. 75-88. • Miller, D., “Micromachining with Abrasive Waterjets,” Proceedings of the 16th International Conference on Jet Cutting Technology, Aix-en-Provence, France, P. Lake, ed., BHR Group Conference Series, October 2002, pp. 59-74. • M. Hashish, “Cutting and drilling at 690 MPa Pressure,” Proceedings of the 10th American Water Jet Conference, WJTA, Houston, Texas, 1999, 137-151.
  • 47. WJTA Short Course ® M. Hashish 47 References (cont.) • Hashish, M., “Controlled-Depth Milling of Isogrid Structures with AWJs,” Manufacturing Science and Engineering, ASME, PED-Volume 68-1, 1994, pp. 413-419. • Hashish, M., “Drilling Deep Small Diameter Holes using Abrasive-Waterjets,” Proceedings of the 16th International Conference on Jet Cutting Technology, Aix-en-Provenece, France, P. Lake, ed., BHR, October 2002, pp. 103-117. • Hashish, M., “Observations on Precision Turning with AWJ,” Proceedings of the 15th International Conference on Jet Cutting Technology, Ronneby, Sweden, R. Ciccu, ed., BHR Group Conference Series, Publication No 41, September 2000, pp. 367-380. • Ramulu, M., Kunaporn, S., Alora, D., Hashish, M., and Hopkins, J., “Waterjet Machining and Peening of Metals," Journal of Pressure Vessel Technology, Transactions of the ASME V.122, No.1, 2000, ASME, pp. 90-95.