Simulations and Experiments on Abrasive Water Jet Machining Based on Fluid Self-excitation

doi:10.3969/j.issn.1004-132X.2022.03.004

Abstract

Abstract: To precisely machine advanced ceramics with enhanced machining efficiency, a new type of water jet machining method was proposed based on fluid self-excitation, termed self-excited oscillating abrasive water jet machining(SEO-AWJM). ANSYS Fluents large eddy simulation model was used for fluid simulation. Simulation results show that with the inlet velocity of 135 m/s and the cavity length of 4 mm, the downstream nozzle outlet pulse rate reaches a maximum of 28.47%. The pulse characteristics of the jet beam cause periodically changes of stagnant layer of workpiece surfaces. Thereby a higher peak wall shear force was obtained and the force reciprocated on workpiece surfaces. SEO-AWJM experiments were conducted, the length of the chamber was adjusted to obtain the best fluid self-excited effectiveness, and silicon nitride substrate was processed. Experimental results show that after 10min fixed-point machining, the maximum removed depth is as 7.5 μm with abrasive water jet machining(AWJM)，while it is as 9.4 μm with SEO-AWJM. The initial surface roughness value Ra was 108.9 nm. After 6 times of AWJM, Ra reaches a stable value of 47.9 nm, after 4 times of SEO-AWJM, Ra reaches a stable value of 51.3 nm.

Key words: self-excited oscillating, abrasive jet, machining, ceramics

摘要： 针对先进陶瓷材料的高效、精密加工，提出了一种基于流体自激的新型磨料水射流加工方法——自激振荡磨料水射流加工(SEO-AWJM)。采用ANSYS Fluent大涡模拟模型进行了流体仿真，仿真结果表明：当入口流速为135 m/s，腔长为4 mm时，下游喷嘴出口脉冲率最大达到28.47%。射流束的脉冲特性使得工件表面停滞层周期性变化，从而获得更高的峰值壁面剪切力，且该力在工件表面往复移动。通过SEO-AWJM实验，调节腔室长度获得最佳流体自激效果并对氮化硅基片进行加工。实验结果表明：定点加工10 min，使用磨料水射流加工去除最大深度为7.5 μm，使用SEO-AWJM去除最大深度为9.4 μm。初始表面粗糙度Ra为108.9 nm，磨料水射流加工6次后，Ra达到稳定值47.9 nm，SEO-AWJM加工4次后，Ra达到稳定值51.3 nm。

关键词: 自激振荡, 磨料射流, 加工, 陶瓷

CLC Number:

TH161

DENG Qianfa, WANG Yangxiao, YUAN Julong, LYU Binghai, ZHAO Tianchen, WANG Xu, . Simulations and Experiments on Abrasive Water Jet Machining Based on Fluid Self-excitation[J]. China Mechanical Engineering, 2022, 33(03): 279-289.

邓乾发, 汪杨笑, 袁巨龙, 吕冰海, 赵天晨, 王旭, . 基于流体自激的磨料水射流加工仿真与实验[J]. 中国机械工程, 2022, 33(03): 279-289.

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