Strategies in 3 and 5-axis abrasive water jet machining of titanium alloys

L'alliage de titane est généralement utilisé pour les pièces structurelles aéronautiques ayant une taille importante et ainsi que des parois minces tout en devant résister à des efforts considérables. L'usinage de ces pièces est difficile avec les méthodes classiques telles que le fraisage, car les forces de coupe sont élevées et les parois minces peuvent être facilement déformées. L'usinage de l'alliage de titane (Ti6Al4V) par un procédé utilisant un jet d'eau abrasif (AWJ) peut potentiellement être utilisé pour remplacer les méthodes d'usinage conventionnelles. Cependant, la compréhension des différents aspects de ce procédé est insuffisante pour autoriser son industrialisation. Cette thèse présente un modèle de prévision de la profondeur usinée dans deux cas de direction du jet : un jet perpendiculaire à la surface de la pièce et un jet incliné. Dans un premier temps, la compréhension du processus d'enlèvement de matière et de la qualité de surface obtenue est étudiée à travers l'observation de l'influence des paramètres du processus. Dans un second temps, un modèle basé sur la distribution gaussienne des particules abrasives dans le jet d'eau est proposé pour caractériser un passage élémentaire et pour prédire le profil du fond de poche obtenu par une succession de passages élémentaires. Ensuite, une méthodologie d'usinage des coins de poche utilisant un contrôle adaptatif de la vitesse d'avance est présentée. Enfin un nouveau modèle du profil du fond de poche prenant en compte l'angle d'inclinaison du jet est présenté. Tout au long de ce travail de thèse, la validation expérimentale a montré un bon accord entre les valeurs mesurées et modélisées et a ainsi démontré la capacité du jet d'eau abrasif à usiner à une profondeur contrôlée.Titanium alloy is generally used for aeronautical structural parts having a large size and as thin walls while having to withstand considerable effort. Machining these parts is difficult with conventional methods such as milling, because the high cutting forces can easily deform the part. Machining of titanium alloy (Ti6Al4V) by an abrasive water jet (AWJ) process can potentially be used to replace conventional machining methods. However, the understanding of the different aspects of this process is insufficient to allow its industrialization. This thesis presents a model of prediction of the machined depth in two cases of direction of the jet: a jet perpendicular to the surface of the part and an inclined jet. At first, the understanding of the removal material process and the obtained surface quality is studied through the observation of the influence of the process parameters. In a second step, a model based on the Gaussian distribution of abrasive particles in the water jet is proposed to characterize an elementary pass and to predict the pocket bottom profile obtained by a succession of elementary passes. Then, a method to machine pocket corners using an adaptive control of the feed rate is presented. Finally, a new model of the pocket bottom profile taking into account the angle of inclination of the jet is presented. Throughout this thesis work, the experimental validation showed a good agreement between the measured and modeled values and thus demonstrated the ability of the abrasive water jet milling to machine to a controlled depth

A Study of the Abrasive Waterjet Machining Process for Carbon Fibre-Reinforced Polymers

Following a comprehensive literature review on the progress of abrasive waterjet (AWJ) machining, an experimental study of the AWJ machining of carbon fibre-reinforced polymers (CFRPs) of various thicknesses was conducted, showing that clean cuts can be achieved with good processing rates. The effect of process parameters on the machined kerf and hole characteristics is amply discussed in the thesis. It was demonstrated that AWJ machining is a good process for thick CFRPs that other processes may be unable to cut. However, material delamination in the form of edge pop-up in the jet entry and push-out at the jet exit caused by the initial pure waterjet impact of an AWJ piercing operation was observed. It was experimentally shown that using a steel mask on top of the workpiece can eliminate pop-up delamination, while push-out delamination at the jet exit can be reduced or eliminated by proper process parameters. However, the mechanisms involved require further investigation. Mathematical models for predicting the major machining performance indicators were developed using dimensional and regression analysis. Experimental verification confirms that the predictive models are reasonable and reliable for assisting in the planning of AWJ machining processes. A computational model is developed and verified experimentally to study the interaction between a pure waterjet and CFRPs. The behaviour of the waterjet is modelled using the smoothed particle hydrodynamics method while the CFRP is modelled by finite element using a continuum damage material model and cohesive zone method. A computational study using the developed model reveals that the material pop-up delamination is initiated due to the material’s elastic response to a rapid release of shock pressure to stagnation pressure and the traverse shear stresses induced by the downward bending of the laminated layers. The pure waterjet impact causes flow divergence and a hydro wedging effect between the material plies, which propagates the delamination. The delamination magnitude is found to increase initially with waterjet pressure up to a threshold after which a change in pressure does not affect the pop-up delamination significantly. The smallest pop-up delamination area occurs on the [0]12 laminate, followed by the [0/45/90/-45/0/45]s and [0/90]3s laminate. It is also found that the push-out loading towards the jet exit and the hydro wedging effect act jointly to result in push-out delamination

Modelling of abrasive waterjet milled footprints

Abrasive waterjet (AWJ) cutting is one of the most promising fast emerging non-traditional cutting technologies. It is highly competitive for machining difficult-to-cut materials like ceramics, composites and titanium alloys as compared to other nonconventional processes (e.g. laser, EDM) which are either technologically inappropriate or fail to be cost-effective. However, at the moment most of the usage of the AWJ machining lies in the area of the through cutting applications and to perform controlled depth cutting (milling) is still at craftsmanship level. This is due to the facts that: (i) AWJ machining is based on employing a jet plume as a "soft body" tool, the footprint of which not only depends on the jet energy parameters (e.g. pressure, abrasive mass flow rate, etc) but also on the jet kinematic parameters (e.g. jet traverse speed) which make controlling of the jet penetration depth very difficult; (ii) there is absence of the appropriate and reliable models that can simulate and predict the AWJ milled footprints and this is one of the major obstructions constraining the use of the AWJ milling applications. The aim of this thesis is to develop accurate models for predicting the A WJ milled footprints. The workpiece material considered is a titanium based superalloy (Ti-6Al- 4V) which is extensively used in the aerospace and medical industry. Two modelling approaches; finite element (FE) modelling and mathematical modelling are presented in this work. Considerable numbers of experiments are conducted to generate the data for validating the results from the models. The models presented in the current study are closer to the real life conditions occurring during the A WJ machining as compared to the state of the art in modelling of AWJ machining. Regarding the FE modelling, the abrasive particles (i.e. garnet) are modeled as elastic with a tensile failure criterion with various non-spherical shapes (rhombic, triangular and trapezoidal) and sharp cutting edges in contrast to the usual approach of assuming them as rigid spherical particles. The effects of mass flow rate of the abrasive particles, traverse speed of the AWJ plume across the workpiece and Gaussian spatial distribution of the abrasive particles in the jet plume are also incorporated in the FE model. The FE model is developed to an extent that it can simulate the footprints as a result of overlapping passes of the AWJ. The simulated jet footprints from the FE models are in good agreement (maximum errors ≤ 15%) with the experimental results. From the mathematical modelling point of view, a model is developed that can accurately predict the AWJ milled footprints with root-mean-squared errors less than 9%. The model takes into account the effects of jet incidence angles, traverse speeds and arbitrarily-moving jet-paths within the target surface. The model is computationally inexpensive and can be used for real time predictions of footprints during CNC machining. The current study provides the reliable models that can be employed for accurate prediction of the abrasive waterjet milled footprints at various process parameters which is a necessary step towards the exploitation of the A WJ machining for controlled depth cutting applications and its automation

Modelling of abrasive waterjet milled footprints

Abrasive waterjet (AWJ) cutting is one of the most promising fast emerging non-traditional cutting technologies. It is highly competitive for machining difficult-to-cut materials like ceramics, composites and titanium alloys as compared to other nonconventional processes (e.g. laser, EDM) which are either technologically inappropriate or fail to be cost-effective. However, at the moment most of the usage of the AWJ machining lies in the area of the through cutting applications and to perform controlled depth cutting (milling) is still at craftsmanship level. This is due to the facts that: (i) AWJ machining is based on employing a jet plume as a "soft body" tool, the footprint of which not only depends on the jet energy parameters (e.g. pressure, abrasive mass flow rate, etc) but also on the jet kinematic parameters (e.g. jet traverse speed) which make controlling of the jet penetration depth very difficult; (ii) there is absence of the appropriate and reliable models that can simulate and predict the AWJ milled footprints and this is one of the major obstructions constraining the use of the AWJ milling applications. The aim of this thesis is to develop accurate models for predicting the A WJ milled footprints. The workpiece material considered is a titanium based superalloy (Ti-6Al- 4V) which is extensively used in the aerospace and medical industry. Two modelling approaches; finite element (FE) modelling and mathematical modelling are presented in this work. Considerable numbers of experiments are conducted to generate the data for validating the results from the models. The models presented in the current study are closer to the real life conditions occurring during the A WJ machining as compared to the state of the art in modelling of AWJ machining. Regarding the FE modelling, the abrasive particles (i.e. garnet) are modeled as elastic with a tensile failure criterion with various non-spherical shapes (rhombic, triangular and trapezoidal) and sharp cutting edges in contrast to the usual approach of assuming them as rigid spherical particles. The effects of mass flow rate of the abrasive particles, traverse speed of the AWJ plume across the workpiece and Gaussian spatial distribution of the abrasive particles in the jet plume are also incorporated in the FE model. The FE model is developed to an extent that it can simulate the footprints as a result of overlapping passes of the AWJ. The simulated jet footprints from the FE models are in good agreement (maximum errors ≤ 15%) with the experimental results. From the mathematical modelling point of view, a model is developed that can accurately predict the AWJ milled footprints with root-mean-squared errors less than 9%. The model takes into account the effects of jet incidence angles, traverse speeds and arbitrarily-moving jet-paths within the target surface. The model is computationally inexpensive and can be used for real time predictions of footprints during CNC machining. The current study provides the reliable models that can be employed for accurate prediction of the abrasive waterjet milled footprints at various process parameters which is a necessary step towards the exploitation of the A WJ machining for controlled depth cutting applications and its automation

Modeling and simulation of surface generation in manufacturing

The paper describes the state-of-the-art in modeling and simulation of surface texture and topography generation at micro and nano dimensional scales. Three main classes of manufacturing processes used for the generation of engineering surfaces are considered: material removal processes, material conservative processes, and material additive processes. Types of modeling techniques for the simulation of surface generation are reviewed and discussed including analytical models, numerical multi-physics models, and data-driven methods. After presenting the application of those modeling techniques for the prediction of characteristics and geometry of surfaces generated by different manufacturing processes, their performance, implementation, and accuracy are discussed. Finally, a roadmap for the realization of a complete surface generation digital twin in manufacturing is outlined

Surface integrity in metal machining - Part I: Fundamentals of surface characteristics and formation mechanisms

The surface integrity of machined metal components is critical to their in-service functionality, longevity and overall performance. Surface defects induced by machining operations vary from the nano to macro scale, which cause microstructural, mechanical and chemical effects. Hence, they require advanced evaluation and post processing techniques. While surface integrity varies significantly across the range of machining processes, this paper explores the state-of-the-art of surface integrity research with an emphasis on their governing mechanisms and emerging evaluation approaches. In this review, removal mechanisms are grouped by their primary energy transfer mechanisms; mechanical, thermal and chemical based. Accordingly, the resultant multi-scale phenomena associated with metal machining are analyzed. The contribution of these material removal mechanisms to the workpiece surfaces/subsurface characteristics is reviewed. Post-processing options for the mitigation of induced surface defects are also discussed

Remanufacturing and Advanced Machining Processes for New Materials and Components

"Remanufacturing and Advanced Machining Processes for Materials and Components presents current and emerging techniques for machining of new materials and restoration of components, as well as surface engineering methods aimed at prolonging the life of industrial systems. It examines contemporary machining processes for new materials, methods of protection and restoration of components, and smart machining processes. • Details a variety of advanced machining processes, new materials joining techniques, and methods to increase machining accuracy • Presents innovative methods for protection and restoration of components primarily from the perspective of remanufacturing and protective surface engineering • Discusses smart machining processes, including computer-integrated manufacturing and rapid prototyping, and smart materials • Provides a comprehensive summary of state-of-the-art in every section and a description of manufacturing methods • Describes the applications in recovery and enhancing purposes and identifies contemporary trends in industrial practice, emphasizing resource savings and performance prolongation for components and engineering systems The book is aimed at a range of readers, including graduate-level students, researchers, and engineers in mechanical, materials, and manufacturing engineering, especially those focused on resource savings, renovation, and failure prevention of components in engineering systems.

Remanufacturing and Advanced Machining Processes for New Materials and Components

"Remanufacturing and Advanced Machining Processes for Materials and Components presents current and emerging techniques for machining of new materials and restoration of components, as well as surface engineering methods aimed at prolonging the life of industrial systems. It examines contemporary machining processes for new materials, methods of protection and restoration of components, and smart machining processes. • Details a variety of advanced machining processes, new materials joining techniques, and methods to increase machining accuracy • Presents innovative methods for protection and restoration of components primarily from the perspective of remanufacturing and protective surface engineering • Discusses smart machining processes, including computer-integrated manufacturing and rapid prototyping, and smart materials • Provides a comprehensive summary of state-of-the-art in every section and a description of manufacturing methods • Describes the applications in recovery and enhancing purposes and identifies contemporary trends in industrial practice, emphasizing resource savings and performance prolongation for components and engineering systems The book is aimed at a range of readers, including graduate-level students, researchers, and engineers in mechanical, materials, and manufacturing engineering, especially those focused on resource savings, renovation, and failure prevention of components in engineering systems.

Remanufacturing and Advanced Machining Processes for New Materials and Components

Remanufacturing and Advanced Machining Processes for Materials and Components presents current and emerging techniques for machining of new materials and restoration of components, as well as surface engineering methods aimed at prolonging the life of industrial systems. It examines contemporary machining processes for new materials, methods of protection and restoration of components, and smart machining processes. • Details a variety of advanced machining processes, new materials joining techniques, and methods to increase machining accuracy • Presents innovative methods for protection and restoration of components primarily from the perspective of remanufacturing and protective surface engineering • Discusses smart machining processes, including computer-integrated manufacturing and rapid prototyping, and smart materials • Provides a comprehensive summary of state-of-the-art in every section and a description of manufacturing methods • Describes the applications in recovery and enhancing purposes and identifies contemporary trends in industrial practice, emphasizing resource savings and performance prolongation for components and engineering systems The book is aimed at a range of readers, including graduate-level students, researchers, and engineers in mechanical, materials, and manufacturing engineering, especially those focused on resource savings, renovation, and failure prevention of components in engineering systems

Remanufacturing and Advanced Machining Processes for New Materials and Components

Remanufacturing and Advanced Machining Processes for Materials and Components presents current and emerging techniques for machining of new materials and restoration of components, as well as surface engineering methods aimed at prolonging the life of industrial systems. It examines contemporary machining processes for new materials, methods of protection and restoration of components, and smart machining processes. • Details a variety of advanced machining processes, new materials joining techniques, and methods to increase machining accuracy • Presents innovative methods for protection and restoration of components primarily from the perspective of remanufacturing and protective surface engineering • Discusses smart machining processes, including computer-integrated manufacturing and rapid prototyping, and smart materials • Provides a comprehensive summary of state-of-the-art in every section and a description of manufacturing methods • Describes the applications in recovery and enhancing purposes and identifies contemporary trends in industrial practice, emphasizing resource savings and performance prolongation for components and engineering systems The book is aimed at a range of readers, including graduate-level students, researchers, and engineers in mechanical, materials, and manufacturing engineering, especially those focused on resource savings, renovation, and failure prevention of components in engineering systems