Multiphase Flow and Wear in the Cutting Head of Ultra-high Pressure Abrasive Water Jet

Abrasive water jet cutting technology is widely applied in the materials processing today and attracts great attention from scholars, but many phenomena concerned are not well understood, especially in the internal jet flow of the cutting head at the condition of ultra-high pressure. The multiphase flow in the cutting head is numerically simulated to study the abrasive motion mechanism and wear inside the cutting head at the pressure beyond 300 MPa. Visible predictions of the particles trajectories and wear rate in the cutting head are presented. The influences of the abrasive physical properties, size of the jewel orifice and the operating pressure on the trajectories are discussed. Based on the simulation, a wear experiment is carried out under the corresponding pressures. The simulation and experimental results show that the flow in the mixing chamber is composed of the jet core zone and the disturbance zone, both affect the particles trajectories. The mixing efficiency drops with the increase of the abrasive granularity. The abrasive density determines the response of particles to the effects of different flow zones, the abrasive with medium density gives the best general performance. Increasing the operating pressure or using the jewel with a smaller orifice improves the coherency of p articles trajectories but increases the wear rate of the jewel holder at the same time. Walls of the jewel holder, the entrance of the mixing chamber and the convergence part of the mixing tube are subject to wear out. The computational and experimental results give a qualitative consistency which proves that this numerical method can provide a reliable and visible cognition of the flow characteristics of ultra-high pressure abrasive water jet. The investigation is benefit for improving the machining properties of water jet cutting systems and the optimization design of the cutting head.

基于GA-GRNN的AWJ强化3D打印AlSi10Mg表面性能实验研究

为提高磨料水射流(Abrasive Water Jet,AWJ)强化工艺对3D打印AlSi10Mg表面性能的强化效果预测的准确性及高效性,首先开展磨料水射流强化AlSi10Mg表面强化实验;然后分别以表面硬度和表面残余应力作为目标,基于遗传算法-广义回归神经网络(Genetic Algorithm-Generalized Ragression Neural Network,GA-GRNN)对实验数据样本进行训练,建立3D打印AlSi10Mg表面性能预测模型;最后,利用遗传算法对建立的神经网络预测模型中的AWJ强化主要参数进行优化。研究结果表明,经过磨料水射流强化后的AlSi10Mg表面硬度与表面残余应力均得到有效提高;建立的GA-GRNN预测模型与校验值误差在2.3%以内,具有较高的准确性;经遗传算法优化后,得到表面硬度最佳参数组合:射流压力为33 MPa,磨料粒径为0.15 mm,靶距为12.4 mm,此时表面硬度为159.25HV;表面残余应力最佳参数组合:射流压力为40 MPa,磨料粒径为0.13 mm,靶距为15 mm,此时表面残余应力为-137.4 MPa。为后续磨料水射流强化零件表面的参数选择提供数据支撑。

Energy Consumption in Comminution of Mica with Cavitation Abrasive Water Jet

We have studied the efficiency of energy consumption in the comminution of mica powder with cavitation abrasive water jet technology. The energy required to create new surfaces in the comminution of mica powder with cavitation abrasive water jet was calculated,in order to estimate its efficiency of energy consumption. The particle size distribution and the specific surface area were measured by applying a JEM-200CX transmission electron microscope and an Autosorb-1 automatic surface area analyzer. The study results show that the efficiency of energy consumed in creating new surface areas is as high as 2.92%,or 4.94% with the aid of cavitation in the comminution of mica powder. This efficiency will decrease with an increase in the number of comminutions. After three comminutions,the efficien-cies will become 1.91% and 2.29% for comminution without cavitation and with cavitation,respectively. The abrasive water jet technology is an effective way for comminution of mica powder.

Numerical Simulation Research of Liquid-Solid Two-Phase Flow in Abrasive Water Jet Nozzle

According to the Lagrange discrete phase model of multiphase flow, mathematical model of the abrasive water-jet （AWJ） nozzle based on the multi-phase movement was introduced, then the boundary conditions was determined and the liquid-solid turbulence which is isothermal, can not be compressed and steadystate in the cone-cylinder nozzles of the export of the pre-mixed AWJ was simulated applying the software FLUENT. The results showed that： the axial velocity and dynamic pressure of the continuous phase in the nozzle were axial symmetry notable, and at the axis had a extreme point; abrasive accelerated at two points, in front contractive segment, the rate increased rapidly, and in the back straight one, the speed accelerated slowly. The length of the cylinder is 100 mm, the diameter of the nozzle is 8 mm, and the angle of the cone is 15°. There is a extreme point of the rate at the point 10 mm in the established model. The results of simulation laid the foundation for optimizing the nozzle structure, improving efficiency and developing the nozzle.

Portable mixed abrasive water jet equipment for rescue in high gas mine shaft

In order to rescue a trapped miner and clean out roadways quickly in a high gas mine shaft after a mining mishap, a special portable cold-cutting equipment is needed, the main technology parameters were calculated according to the advanced cold-cutting technology of high pressure abrasive water jet and the portable mixed abrasive water jet equipment （PAWE） was designed to meet the needs of emergency rescue in high gas mine shafts. Tested the PAWE in a high gas environment, and the result shows that the maximum cutting depth of solid iron pipe is 18 mm and the recoilforce of the sprayer is 28.9 N under the conditions that actual cutting pressure is 29 MPa, starting target distance is 10 ram, cutting speed is 180 mm/min and concentration of abrasive is 32%. The course of the experiment in the high gas environment was smooth and continuous, without any explosion. The PAWE is easy to move and operate, but the nozzle which was worn badly in the sprayer should be changed every 8 minutes.

Performance of recycling abrasives in rock cutting by abrasive water jet

Rock cutting performance of recycling abrasives was investigated in terms of cutting depth, kerf width, kerf taper angle and surface roughness. Gravity separation technique was employed to separate the abrasives and the rock particles. The recycling abrasive particles were then dried and sieved for determination of their disintegration behaviors. Before each cutting with recycling abrasives, the abrasive particles less than 106 ?m were screened out. It is revealed that a considerable amount of used abrasives can be effectively reused in the rock cutting. The reusabilities of abrasives are determined as 81.77%, 57.50%, 34.37% and 17.72% after the first, second, third and fourth cuttings, respectively. Additionally, it is determined that recycling must be restricted three times due to the excessive disintegration of abrasives with further recycling. Moreover, it is concluded that cutting depth, kerf width and surface roughness decreases with recycling. No clear trend is found between the kerf taper angle and recycling. Particle size distribution is determined as an important parameter for improving the cutting performance of recycling abrasives.

Rapid manufacturing of SiC molds with micro-sized holes using abrasive water jet

Silicon carbide (SiC) is highly wear resistant with good mechanical properties, including high temperature strength, excellent chemical resistance, and high thermal conductivity and thermal shock resistance. SiC molds, which can be produced with diverse microstructural features, are now widely used in glass molding owing to their excellent characteristics, and also have potential applicability in IT industries. SiC molds are traditionally fabricated by silicon micromachining or dicing. The fabrication cost of silicon micromachining is very high, however, because several expensive masks are needed. Furthermore, the fabrication time is very long. Meanwhile, it is difficult to make micro-patterned molds with arbitrary shapes using dicing saws. Abrasive water jet (AWJ) is widely applied to cut and drill very brittle, soft and fibrous materials. It offers high energy density, the absence of a heat affected zone(HAZ), high performance, and an environment friendly process. In spite of these advantages, micro-hole drilling via conventional AWJ processing suffers from notable shortcomings. We proposed a new abrasive supplying method of AWJ. The proposed method reduces frosting phenomena, and provides micro-machining of AWJ. The characteristics of a hole machined was investigated by the proposed AWJ process according to the ratio of water and abrasives. With the optimal experimental conditions, 3×3 array SiC molds with the diameter of 700 μm and depth of 900 μm were successfully manufactured.

Experimental study on landscape of CFRP cutting by abrasive water jet

To investigate the influence of operation parameters of abrasive water jet on surface roughness of carbon fiber reinforced plastic(CFRP),experimental studies were conducted.The three-dimensional landscape of cutting front was reconstructed according to the measured data byμscan laser confocal microscopy.Fourier spectral analysis was also adopted to study surface structure in detail.It is found that the morphology of cutting front is similar to that of other materials.In the smooth cutting zone,the fluctuation of amplitudes of surface profile is gentler,compared with that in the rough cutting zone.The lower part of the rough cutting zone was characterized by the periodical appearance of peaks and valleys.The roughness of surface increases with the increase of depth.While in the smooth cutting zone and part of rough cutting zone,roughness increases with the increase of traverse speed.For the thickness of samples,in the smooth cutting zone,the roughness increases with the increase of depth.The dominant harmonic component in the surface profile is concentrated in a narrow range from 0 to 10 Hz,and the relatively higher density of frequency from 10 to 50 Hz is shown in the rough cutting zone,which is caused by the interaction between perpendicular abrasive water jet and reflect jet.

Comminution of Mica by Cavitation Abrasive Water Jet

The comminution of mica with an abrasive water jet is mainly based on three knids of effects, that is, high-speed collision, cavitating effect and shearing effect. Cavitation abrasive water jet was applied for the comminution of mica because cavitation abrasive water jet can make full use of the three effects mentioned above. Besides high speed impacting among particles,cavitation and shearing were also enhanced due to the divergent angle at the outlet of the cavitation nozzle.A JME-200CX transmission electron microscope was used for observing the size distribution of particles.Variance analysis on the experimental results indicates that the effect of cavitation is much more significant than that of collision.The effect of pressure on comminution results becomes less with the decrease of the particle size.

Orthogonal design of experiment and analysis of abrasive water jet cutting on carbon fiber reinforced composites

The carbon fiber reinforced composite is a new type of composite material with an excellent property in strength and elastic modulus,and has found extensive applications in aerospace,energy,automotive industry and so on.However,this composite has a strict requirement on processing techniques,for example,brittle damage or delamination often exists in conventional processing techniques.Abrasive water jet machining technology is a new type of green machining technique with distinct advantages such as high-energy and thermal distortion free.The use of abrasive water jet technique to process carbon fiber composite materials has become a popular trend since it can significantly improve the processing accuracy and surface quality of carbon fiber composite materials.However,there are too many parameters that affect the quality of an abrasive water jet machining.At present,few studies are carried out on the parameter optimization of such a machining process,which leads to the unstable quality of surface processing.In this paper,orthogonal design of experiment and regression analysis were employed to establish the empirical model between cutting surface roughness and machining process parameters.Then a verified model was used to optimize the machining process parameters for abrasive water jet cutting carbon fiber reinforced composites.

INVESTIGATION ON NEW TYPE OF DOUBLY BLENDING ABRASIVE WATER JET NOZZLE SYSTEM WITH HIGHER PERFORMANCE

Based on the two existing abrasive water-jet（AWJ） systems, the dia-jet （or pre-jet） and the post-jet, a new type of abrasive water-jet system is put forward, which combines the dia-jet＇s advantage, low operating system pressure, slender stream jet, and more concentrative abrasive in the blended stream, with merits of post-jet, the less sophisticate apparatus, successive supply of abrasives. The theoretic analysis is brought out in detail, and the nozzle system structure is concisely illustrated. Its relevant experiment results are demonstrated, proving that this new system is effective in various aspects, enlarging penetrating capability without raising system pressure, saving machining power supply, lessening energy loss, etc.

Research and application of water jet technology in well completion and stimulation in China

In recent years, rapid progress in the use of high pressure water jets （HPWJ） has been made in oil and gas well drilling, completion, and stimulation; and good results have been achieved in field applications. Advances in technologies and developments of well completion and stimulation with hydrajet are reviewed in this paper. Experiments were conducted to study the characteristics of abrasive water jetting and to optimize jet parameters, which can provide methods for the well completion and hydrajet fracturing. Deep-penetrating hydrajet perforating can create a 2-3 m clean hole with a diameter of 20-35 mm. Multilayer hydrajet fracturing is a process whereby multiple layers are stimulated in a single run without using mechanical packers, thereby reducing operation procedure and risk. Multilateral radial wells can be drilled using hydraulic jetting up to 100 m in length. The technique to remove sand particles and plugs with rotating self-resonating cavitating water jets in horizontal wellbores has been developed and oilfield-tested, which shows promising, cost effective prospects.

基于声发射的超声辅助AWJ冲蚀实验研究

超声辅助磨料水射流具有良好的流动特性,有效提高了射流的加工效率与精度。为了进一步研究其冲蚀能力,通过实验研究了超声辅助磨料水射流(AWJ)冲蚀动态响应规律,基于声发射检测技术研究了超声辅助磨料水射流冲蚀动态响应情况,对信号进行采集处理,分析了射流压力、靶距以及超声振幅等参数对其冲蚀动态响应的影响规律。结果表明:声信号随着射流压力的增大而不断增强,冲蚀深度不断增大;随着靶距与超声振幅的不断增大,声信号呈现先变强后变弱的趋势,冲蚀深度先增大后减小,即存在最佳靶距与最佳超声振幅;声信号频率主要分布于0~200kHz之间。

含磨料脉冲射流破岩效果试验研究

为探究脉冲磨料水射流的破岩效果,选用五种不同强度的硬岩,开展了脉冲纯水/磨料水射流破岩试验,并以冲蚀孔尺寸为指标,将脉冲纯水/磨料水射流的破岩效果同连续纯水/磨料水射流进行了对比。结果表明:连续磨料水射流冲蚀岩体过程主要依赖磨料粒子的磨削作用,而脉冲磨料水射流则是连续的水锤效应和磨料粒子磨削作用的叠加;无磨料粒子时,连续水射流破岩主要依赖射流初期的单个水锤效应,而脉冲水射流则是多个连续的水锤压力持续冲击岩石,导致岩体表面出现破碎区。

储气库救援井磨料水射流管外开窗试验研究

针对井筒不完整和存在落鱼的废弃事故老井出现井下封堵困难和气窜问题,如何实现有效封堵已成为老井改造储气库的关键。为此开展了储气库救援井磨料水射流钻杆成孔试验。试验结果表明:随着喷射距离的增大,单位时间内钻杆成孔深度显著减小;随着喷射压力的增大,钻杆成孔所需的时间缩短;钻杆成孔所需的最佳磨料质量分数为6%~8%,磨料粒径分布在40~60目范围内,可实现较好的破坏效果。通过正交试验分析认为,钻杆成孔的极限喷距随着喷射压力的增大而增大,随着喷射距离增大而减小;为缩短作业时间,应调整参数为高喷射压力(>25 MPa)和短喷射距离(<20 cm)。所得结论可为现场作业提供技术借鉴。

可降解软磨料对再制造水射流清洗性能影响因素研究

提出一种新型可降解软磨料用于磨料水射流清洗技术,分析对比不同硬度磨料水射流清洗再制造零部件的清洗性能和表面损伤规律.采用石榴石硬磨料水射流、核桃壳软磨料水射流和纯水射流3种射流方式,开展清洗零部件污垢的对比试验;在不同清洗方式下,分析清洗速率、比能耗、清洗后表面粗糙度、最大坑深等4个方面的差异,并从宏观和微观层面分析不同清洗模式下基体损伤情况.结果表明,核桃壳软磨料能够有效去除表面污垢和杂质,降低比能耗,提高清洗速率,同时又不会对基体表面产生较大的损伤,在再制造业清洗或对表面粗糙度要求高的场合下,是一种较为理想的选择.

基于ALE-FEM耦合算法的磨料水射流破岩数值模拟及其机理分析

磨料水射流在钻井提速、深穿透射孔和压裂增产等方面应用效果显著,深入认识磨料水射流破岩机理是提升其应用效果的关键之一。本文基于任意拉格朗日—欧拉耦合有限单元算法,提出了独立封装有限元网格描述磨料的方法,将水射流单元设定网格随物质的运动而变化以实现流体流动特性,速度设置给物质;将磨料单元设定网格不随物质的运动而变化以实现固体颗粒特性,速度设置给网格。综合考虑岩石的动态冲击损伤作用以及水射流和磨料的协作,建立了可表征水射流流动和岩石损伤破坏的多相多物理场耦合过程的磨料水射流破岩模型,模型聚焦磨料颗粒和水射流对岩石微秒级的冲击破坏。采用2套网格捕捉磨料和水射流的协同破岩作用,得到了岩石破碎体积、岩石损伤场、水射流压力场、水射流和磨料对岩石破碎的能量贡献率等关键参数的时空演化特征。结果表明,磨料水射流破岩过程磨料起主导作用,水射流起辅助作用。分析得到磨料水射流中磨料—水射流协同破岩机理认识,磨料撞击岩石使岩石局部产生的高程度损伤降低了水射流破岩的难度,此外磨料冲击破碎岩石使得水射流和岩石之间产生新界面,促使水射流的冲击压力升高,提高了水射流的破岩能力,因此磨料水射流中的水相比于纯水射流具有更高的射流打击力和能量利用率,磨料冲击预损伤岩石叠加水射流聚集增压的磨料—水射流协同作用破岩是磨料水射流破岩效率和能量利用率高于纯水射流数倍的重要机理之一。研究结果对优化磨料水射流破岩参数提供了理论模型和设计依据。

磨料水射流切削皮质骨断面形貌特征研究

为探索磨料水射流切削过程中对皮质骨材料的切削机理,提高切削断面质量,分别以石榴石、氯化钠为磨料对皮质骨进行切削,对比不同切削方向下断面粗糙度变化规律以及微观划痕特征.实验结果表明,断面粗糙度数值均呈现先减小后增大的特点,依据表面粗糙度数值将断面分为初始区、光滑区、粗糙区3部分.当使用磨料为氯化钠,切削方向垂直于骨单元时,断面粗糙度平均值分别是切削方向平行和横向于骨单元时断面粗糙度平均值的1.74倍和1.70倍.当使用磨料为石榴石,切削方向垂直于骨单元时,断面粗糙度平均值分别是切削方向平行和横向于骨单元时断面粗糙度平均值的1.41倍和1.55倍.切削过程中断面形成大量微米级划痕,对比氯化钠、石榴石2种磨料对断面划痕特征的影响,与石榴石相比,当使用磨料为氯化钠时,皮质骨切削断面划痕尺寸偏大,长度、宽度值跨度相近,划痕深度值跨度较大.

微孔的磨料水射流抛光CFD模拟及试验

为解决飞秒激光微孔难以抛光的问题,结合磨料水射流去除函数稳定、自适应性强等特点,采用磨料水射流抛光方法提高飞秒激光微孔质量。利用Fluent软件对不同工艺参数下的磨料水射流微孔抛光过程进行计算流体力学(computational fluid dynamics,CFD)模拟,分析不同参数下的流场分布、侵蚀速率及壁面剪切力作用规律;然后通过响应面法对射流靶距、射流压力及磨料粒径等3因素进行优化试验,以微孔内壁面剪切力均方差为响应值,建立其响应面方程,获得最佳抛光参数组合并进行试验验证。结果表明:射流压力对微孔内壁面剪切力的影响最大,当射流压力从0.80 MPa增至1.50 MPa时,微孔内壁面剪切力增大2倍以上。射流的不同结构段因性质不同可适用于不同工况。利用响应面法分析得到水射流微孔抛光的最佳工艺参数组合是:射流冲击角,90°;射流靶距,3.5 mm;射流压力,1.10 MPa;磨料粒径,15.0μm。在该条件下抛光微孔内壁面的表面粗糙度R_a降至0.354μm。磨料水射流抛光可显著改善微孔壁面质量,且响应面法预测的数据模型有较高准确性。

基于SPH法的磨料射流破损混凝土裂纹扩展及损伤分析

为研究射流冲击下混凝土的破损机理与裂纹扩展规律,基于光滑粒子流体动力学(smooth particle hydrodynamics,SPH)方法建立了磨料水射流冲击混凝土的数值模型,研究了混凝土内部的应力传播和破损方式,磨料体积分数和混凝土的孔隙率与裂纹长度、失效粒子数、坑深和坑径之间的关系。研究表明:裂纹对应力具有强阻碍作用,与边界应力波的反射叠加会使得应力区域性集中,形成中心微裂纹,以及内部破碎块;磨料体积分数为20%与0%相比,裂纹长度增加2.30倍,失效粒子数增加3.38倍,坑深值增加4.00倍,证明射流中添加磨料会大幅提高破损效果;混凝土的孔隙率越大,裂纹分布越发散,损伤区域面积、损伤程度和分形维数越大,证明孔隙会降低混凝土的抗压强度,孔隙率大的材料更易受损。