Rock breaking performance of the newly proposed unsubmerged cavitating abrasive waterjet

To improve the rock breaking ability, cavitating waterjet and abrasive waterjet are combined by using a coaxial low-speed waterjet generated around the periphery of a high-speed abrasive waterjet, and a new type of waterjet called unsubmerged cavitating abrasive waterjet(UCAWJ) is thus produced. The rock breaking performance of UCAWJ was compared with submerged cavitating abrasive waterjet(SCAWJ)and unsubmerged abrasive waterjet(UAWJ) by impinging sandstone specimens. Moreover, the effects of jet pressure, standoff distance, abrasive flow rate and concentration were studied by evaluating the specific energy consumption, and the area, depth, and mass loss of the eroded specimen. The results show that the artificially generated submerged environment in UCAWJ is able to enhance the rock breaking performance under the same operating parameters. Furthermore, the rock breaking performance of UCAWJ is much better at higher jet pressures and smaller standoff distances when compared with UAWJ. The greatest rock breaking ability of UCAWJ appears at jet pressure of 50 MPa and standoff distance of 32 mm, with the mass loss of sandstone increased by 370.6% and the energy dissipation decreased by 75.8%. In addition, under the experimental conditions the optimal abrasive flow rate and concentration are 76.5 m L/min and 3%, respectively.

机匣开槽控制喷水推进器不稳定流动的数值研究

针对喷水推进器小流量工况下的驼峰区不稳定流动,采用计算流体力学方法研究了其失稳特性。结果表明,随着流量的减少,推进泵的扬程和效率显著下降,扬程曲线在0.42Qd~0.8Qd范围内呈现出正斜率的驼峰特性,同时内部流场变得紊乱,并出现流动分离和回流等现象。为了改善这一不稳定流动,采用了机匣开槽技术进行流动控制,使驼峰现象得到明显改善。在最佳槽体结构参数下,深度失速工况点的扬程和效率分别比原模型提高了约147.6%和70.3%。机匣开槽一方面能够对进口来流进行整流,起到减少预旋和增大轴向进流速度的作用,另一方面可以抑制主流区漩涡的形成以及叶轮进口位置的低频压力脉动。

Effects of Area Discontinuity at Nozzle Inlet on the Characteristics of Self-resonating Cavitating Waterjet

The current research on self-resonating cavitating waterjet（SRCW） mainly focuses on the generation mechanism and structure optimization.Researches relating to the influences of disturbances at nozzle inlet on the characteristics of the jet are rarely available.In order to further improve the performance of SRCW,effects of area discontinuity（enlargement and contraction） are experimentally investigated using three organ-pipe nozzles.Axial pressure oscillation peak and amplitude as well as aggressive erosion intensity of the jet are used to evaluate the effects.The results reveal that area enlargement and contraction affect the peak differently,depending on the inlet pressure,nozzle geometry,and standoff distance;while area contraction always improves the amplitude regardless of these factors.At inlet pressures of 10 MPa and 20 MPa,area discontinuity improves the peak at almost all the testing standoff distances,while this only happens at smaller standoff distances with the inlet pressure increased to 30 MPa.The capability of area discontinuity for improving the amplitude is enhancing with increasing inlet pressure.Moreover,the cavitation erosion ability of the jet can be largely enhanced around the optimum standoff distance,depending on the type of area discontinuity and nozzle geometry.A preliminary analysis of the influence of area discontinuity on the disturbance waves in the flow is also performed.The proposed research provides a new method for effectively enhancing the performance of SRCW.

喷水推进器系泊工况性能的数值模拟

为了分析系泊工况下喷水推进器的内流特性,在系泊试验的基础上采用基于流体体积法(VOF)的计算方法,对喷水推进器的系泊工况内流场特性进行数值模拟研究.对比系泊试验数据发现,基于该方法得到的推进器总推力和转矩与试验数据吻合较好,该方法可以较好地模拟喷水推进器自由喷射流场.从喷水推进器数值模拟结果可知,当叶轮转速增加时,叶轮内部欧拉扬程的增长速度趋于恒定,叶轮的效率增加;叶轮内部熵增较高的区域主要分布在叶轮入口、壁面和叶顶附近,表示该区域流动损失较大,与系泊工况下喷水推进器的进口流道处存在较大程度的流动分离密切相关.

工艺参数对磨料水射流切割钢板效果的影响

基于有限元(FEM)与光滑粒子流体动力学(SPH)耦合方法,利用数值模拟手段研究了磨料水射流切割钢板的加工机理,重点分析了磨料浓度、射流压力、射流角度对切割钢板效果的影响。结果表明,加入磨料的水射流对钢板的切割能力明显提高,切割截面呈“U”型;随着磨料浓度的增大,钢板切割深度呈增加趋势,切口宽度则变化不大;钢板切割深度随射流压力的提高则呈近似线性增加的趋势;当射流角度由垂直(90°)转变为一定倾斜角后,钢板切割深度有所降低,材料的整体去除量略有减少。

对转喷水推进器前后叶轮能量配比对其性能影响的数值研究

面向新型舰船高效推进系统的研制需求,将对转叶轮形式与喷水推进技术相结合,以更高能量密度的能量转化模型代替传统模式。该文采用计算流体力学的数值模拟方法,对基本参数相似、前后叶轮能量配比不同的2种推进方案开展了定常内流场分析与非定常叶轮干涉特性研究,结果表明:2种能量配比的对转喷水推进器推进效率基本相同,适应航速范围广、高效区宽;前叶轮起到了整流作用,降低了进口流道流场不均匀性对后叶轮的影响;增加后转子负载,减小前叶轮负载的能量配比方式有利于对转喷水推进器非定常性能的提升,推进器叶轮激振力与压力脉动幅值下降明显。

伴随方法在喷水推进器进流研究中的应用

进口流道是喷水推进器的主要部件之一,其水力损失是推进器总损失的重要部分。进口流道几何结构引起推进泵非均匀进流,对推进器水力效率和动态激励造成不利影响。该文采用伴随方法对喷水推进器进口流道开展数值研究,先正向求解流动方程后,再反向求解伴随方程,基于伴随变量场得到与进流最相关的流动区域,建立并验证了基于伴随方法的喷水推进器流道进流面获取方法。以进口流道边界为设计输入变量,以出口流动不均匀度为目标,通过伴随方法来优化流道几何,经过8次迭代后,出口不均匀度相对下降幅度达到18.7%,验证该方法可有效优化进口流道几何。

一种系列化喷水推进装置的快速选型方法

船用喷水推进装置通常采用系列化的供货模式。喷水推进供货商依据提供的船舶主尺度、航速、动力系统等输入参数,通过船-机-泵匹配理论从系列化喷水推进产品中选择一型以满足需求。本文提出一种基于系列化喷水推进装置的快速选型方法,在仅已知设计航速和主机功率的条件下可快速选择适当的系列化喷水推进规格。本文方法适用于船舶的前期论证和方案设计阶段,船东或设计人员能利用本方法和喷水推进产品样本来实现快速选型。系列化快速选型的结果经分析误差较小,能够满足工程应用的需求。

水力切割拆除粗苯罐过程中的安全风险防控

对粗苯罐拆除作业过程进行了风险分析辨识,通过对比常用拆除方法的优缺点,确定了最优的施工方法“便携式水力切割”。以某焦化厂苯罐采用便携式水力切割实操拆除为例,提出了针对施工现场、水力切割的特点的安全技术措施,实现了“便携式水力切割苯罐”施工作业全过程安全风险管控。结果表明:使用便携式水力切割拆除焦化厂粗苯罐,可大大降低粗苯罐以及类似易爆有毒储罐拆除施工过程起火爆炸的风险,水力切割技术在粗苯罐及类似易爆有毒储罐拆除施工的方向具有广阔的应用前景,有望为焦化以及其他类似行业的安全、高效生产提供有力的技术支持。

Abrasive Waterjet Machining Simulation by Coupling Smoothed Particle Hydrodynamics /Finite Element Method

In dealing with abrasive waterjet machining（AWJM） simulation,most literatures apply finite element method（FEM） to build pure waterjet models or single abrasive particle erosion models.To overcome the mesh distortion caused by large deformation using FEM and to consider the effects of both water and abrasive,the smoothed particle hydrodynamics（SPH） coupled FEM modeling for AWJM simulation is presented,in which the abrasive waterjet is modeled by SPH particles and the target material is modeled by FEM.The two parts interact through contact algorithm.Utilizing this model,abrasive waterjet with high velocity penetrating the target materials is simulated and the mechanism of erosion is depicted.The relationships between the depth of penetration and jet parameters,including water pressure and traverse speed,etc,are analyzed based on the simulation.The simulation results agree well with the existed experimental data.The mixing multi-materials SPH particles,which contain abrasive and water,are adopted by means of the randomized algorithm and material model for the abrasive is presented.The study will not only provide a new powerful tool for the simulation of abrasive waterjet machining,but also be beneficial to understand its cutting mechanism and optimize the operating parameters.

THE EROSIVE PROCESS IN ABRASIVE WATERJET CUTTING OF POLYMER MATRIX COMPOSITES

A study is carried out which analyzes the machinability of polymer matrix composites under an abrasive waterjet (AWJ) and the associated erosive process or mechanism. It shows that AWJ cutting can produce good quality kerf at high production rate if the cutting parameters are properly selected. A scanning electron microscopy (SEM) analysis of the cut surfaces reveals that the erosive process for the matrix material (resin) involves shearing and ploughing as well as intergranular cracking, while shearing is a dominant process for cutting the fibres in the upper cutting region but the fibers are mostly pulled out in the lower region.

CFD analysis and field observation of tool erosion caused by abrasive waterjet fracturing

Abrasive waterjet(AWJ)fracturing has become an accepted horizontal multistage stimulation technique due to its flexibility and high efficiency of extensive fracture placement.The downhole tool failure of AWJ fracturing becomes an issue in the massive hydraulic fracturing because of high velocity and proppant erosion.This paper proposed a 3D computational fluid dynamics(CFD)-based erosion model by considering high-velocity waterjet impact,proppant shear erosion,and specific inner structure of hydra-jet tool body.The discrete phase approach was used to track the proppant transport and its concentration distribution.Field observation provides strong evidence of erosion patterns and mechanisms obtained from CFD simulation.The results show that the erosion rate has a space dependence in the inner wall of the tool body.The severe erosion areas are primarily located at the entries of the nozzle.Evident erosion patterns are found including a‘Rabbit’s ear’erosion at the upper-layer nozzles and a half bottom loop erosion at the lower-layer nozzles.Erosion mechanisms attribute to high flow velocity at the entry of nozzles and the inertia force of proppant.Sensitivity analysis demonstrates that the pumping rate is a primary factor contributing to erosion intensity.

Application of the fractal theory for evaluating effects of coal comminution by waterjet

Comminution of coal to ultrafine sizes by high-pressure waterjet provides a novel method for preparation of coal-water fuels for next generation,near-zero emission electric power generation.The particle size distribution(PSD)of ground coal is a key parameter in the preparation of slurries as it determines the settling behavior of the particles and viscosity of the coal-water mixture.There are several methods available for representation and evaluation of particle size analysis data.However,fractal theory provides a means by which the entire PSD of comminuted materials can be quantified by using of a specific and exact value.In this paper,a volume-based fractal model was deduced to characterize the PSD of the coal which is ground in a specially designed comminution cell.During the size reduction process,the inlet pressures up to 276 MPa were used.

Longhole waterjet rotary cutting for in-seam cross panel methane drainage

In order to improve the efficiency of gas drainage before and during longwall extraction,a waterjet rotary cutting system has been developed for in-seam cross panel methane drainage.The purpose of the water rotary cutting system developed was to create artificial fractures along the gas drainage boreholes.During the design of the system,it was perceived that the nozzle geometry is one of the key factors,affecting cutting capacity.Therefore,we studied the structural and geometric parameters of the nozzle and optimized its performance during laboratory tests and numerical simulation.Underground trials conducted in a coal mine,indicate that production of gas drainage before and after cutting significantly increased by up to three times.The advantages of waterjet assisted gas drainage method has been identified as:1) increasing gas drainage efficiency,2) a possible development of a gas drainage fractured network within coal seams associated with panel extraction,and 3) reducing the risk of exceeding gas limits during longwalling.

Gas drainage efficiency improvement by increasing coalbed permeability using waterjet cutting system

This paper presented a method to create artificial fractures along the existing gas drainage borehole and increase the permeability of the coalbed using a high pressure waterjet cutting system.The field work conducted in Rujigou Colliery, Shenhua Ningxia Coal Group demonstrate that the coalbed permeability is increased, and accordingly, gas drainage efficiency is improved up to 3 to 6 times over the traditional methods using high pressure waterjet technique.Also, based on the monitoring data, the conceptual model for gas drainage process associated with different mining activities has been proposed, and few major advantages using waterjet assistance method have been identified.

A review on the erosion mechanisms in abrasive waterjet micromachining of brittle materials

The fabrication of miniature structures on components with high-integrity surface quality represents one of the cutting edge technologies in the 21st century.The materials used to construct such small structures are often difficult-to-machine.Many other readily available technologies either cannot realise necessary precision or are costly.Abrasive waterjet(AWJ)is a favourable technology for the machining of difficult-to-machine materials.However,this technology is generally aimed at large stock removal.A reduction in the scale of this technology is an attractive avenue for meeting the pressing need of industry in the production of damage-free micro features.This paper reviews some of the work that has been undertaken at UNSW Sydney about the development of such an AWJ technology,focusing on the system design currently employed to generate a micro abrasive jet,the erosion mechanisms associated with processing some typical brittle materials of both single-and two-phased.Processing models based on the findings are also presented.The review concludes on the viability of the technology and the prevailing trend in its development.

Universal Method for the Prediction of Abrasive Waterjet Performance in Mining

极端采矿条件下的硬岩破碎可采用磨料水射流(AWJ)技术,这种技术能够在不产生粉尘的条件下有效切割难以机械加工的材料。这种技术还可用于爆破、本安和消防安全。就断裂力学而言,每一种可被破坏的材料均可被视为韧性或脆性材料。因此,需要找到一种无论使用AWJ对何种材料进行切割都能精确预测其效率的方法。该问题可通过能量守恒法加以解决,它显示了材料去除量与AWJ动能之间的比例。本文介绍了基于能量守恒法的预测方法,并提出如何达到最有效破坏水平的建议,以及关于涉及磨料流量与水流量、靶距和磨料颗粒粒径关系值的合理范围的建议。本文还提供了基于断裂力学的临时结构法确定材料破坏起始阈值条件的参数。

Impact characteristics and stagnation formation on a solid surface by a supersonic abrasive waterjet

A computational fluid dynamics(CFD)study of the impact characteristics and stagnation formation on a solid target surface by an abrasive waterjet at supersonic velocities is presented to understand the impact process.A CFD model is developed and verified by experimental water and particle velocities and then used to simulate the jet impact process.The trends of the stagnation formation and its effect on the jet flow with respect to the jetting and impacting parameters are amply discussed.It is found that stagnation formation at the impact site increases with an increase in the impact time,nozzle standoff distance and nozzle diameter,while the initial peak velocity at the nozzle exit has little effect on the size of the stagnation zone.It is shown that stagnation markedly changes the water and particle flow direction,so that the particle impact angle is varied and the jet impact area is enlarged.The jet structure may be classified to have a free jet flow region,a jet deflection region with a stagnation zone and a wall jet region.Furthermore,the stagnation affects significantly the waterjet and particle energy transferred to the target surface.The average particle velocity across the jet is reduced by approximately one third due to the damping effect of the stagnation under the conditions considered in this study.

Experiments and computer simulation analysis of impact behaviors of micro-sized abrasive in waterjet cutting of thin multiple layered materials

The abrasive waterjet (AWJ) is now widely used in the advanced cutting processes of polymers,metals,glass,ceramics and composite materials like thin multiple-layered material (TMM).Various research and development efforts have recently been made to understand the science of AWJ.However,the interaction mechanism between a workpiece and high-velocity abrasive particles still remains a complicated problem.In this work,the material removal mechanisms of AWJ such as micro penetration and micro dent were experimentally investigated.In addition,a new computer simulation model considering high strain rate effect was proposed to understand the micro impact behavior of high-velocity micro-sized abrasives in AWJ cutting.

Abrasive WaterJet Machining of Thick Carrara Marble: Cutting Performance vs. Profile, Lagging and WaterJet Angle Assessments

This paper deals with an assessment of the machined surface created by abrasive waterjet technology regarding its cutting performance versus profile, lagging and waterjet angle assessments. The results of the experiments presented in this study are with regard to Carrara marble. The machined surfaces were measured in seven different locations across a 40 mm depth of cut by a high precision contact-type profilometer and thus assessed using the standardized amplitude parameters of the profile distribution. The lagging and waterjet angle were also evaluated by creating a digital photo of the machined surface together with a reference gauge. The existence of machining marks on the machined surface has been mostly noticeable in the bottom zone around ~20 mm depth of cut down to jet exit. This investigation leads to a conclusion that, stand-off distance and traverse rate play the roles of the utmost importance in considerations of the machined surface quality in contrast to abrasive mass flow rate. In addition, while the striation zone (rough surface) cannot be eliminated entirely, by selecting proper process parameters, a smooth cutting machined surface can be accomplished.