Abstract
Part I of this two-part paper presented mixing chamber conditions and jet characteristics in a high-pressure abrasive slurry jet micro-machining (HASJM) system. The present paper describes the modeling of the slurry entrainment process within the mixing chamber and mixing tube of the nozzle using computational fluid dynamics (CFD) and shows how the results can be used to explain and predict machining performance. The slurry flow rate into the mixing chamber was found to have a large impact on the performance of the jet due to differences in the momentum of the high-velocity water and low-velocity slurry. The erosive efficacy of the jet was assessed by machining channels and blind holes in aluminum 6061-T6. Differences in the centerline erosion rates of holes and channels for a given jet showed clear evidence of incubation and stagnation zone effects. The CFD models simulated various slurry flow rates entering the mixing chamber as a result of the low pressure created by the central high-velocity jet of water. They predicted correctly an experimentally observed flooding condition in which slurry completely filled the mixing chamber and mixing tube. The models could also identify the transient conditions leading to the onset of this flooding as the chamber first began to fill, which could not be identified experimentally. Flooding was found to significantly reduce the jet velocity, thus diminishing its erosive efficacy. The models also identified the operating conditions within the mixing chamber that produced boiling due to the low internal pressure generated by the central high-velocity jet of water. This boiling condition was found in part I to result in a wider jet exiting the mixing tube.
Similar content being viewed by others
References
Teti M, Papini M, Spelt JK, (submitted). Jet properties and mixing-chamber flow in a high-pressure abrasive slurry jet: part I—measurement of jet and chamber conditions. Int J Adv Manuf Technol
Nguyen T, Pang K, Wang J (2009) A preliminary study of the erosion process in micro-machining of glasses with a low pressure slurry jet. Key Eng Mater 389:375–380
Pang K, Nguyen T, Fan JM, Wang J (2010) Machining of micro-channels on brittle glass using an abrasive slurry jet. Key Eng Mater 443:639–644
Wang J, Nguyan T, Pang K (2009) Mechanism of microhole formation on glasses by an abrasive slurry jet. J Appl Phys 105(4):044906
Hashish M (1993) Performance of high-pressure abrasive suspension jet system. Am Soc Mech Eng 67:199–207
Liu HT (1998). Near-net shaping of optical surfaces with abrasive suspension jets. 14th Int. conference on jetting technology, Brugge, 285–294
Haghbin N, Ahmadzadeh F, Spelt JK, Papini M (2016) High pressure abrasive slurry jet micro-machining using slurry entrainment. Int J Adv Manuf Technol 84(5–8):1031–1043
Narayanan C, Balz R, Weiss DA, Heiniger K (2013) Modelling of abrasive particle energy in water jet machining. J Mater Process Technol 213(12):2201–2210
Momber AW (2001) Energy transfer during the mixing of air and solid particles into a high-speed waterjet: an impact-force study. Exp Thermal Fluid Sci 25(1):31–41
Narayanan C, Caviezel D, Lakehal D (2016). Optimization of abrasive waterjet nozzle design for precision and reduced wear using compressible multiphase CFD modelling. Proc. 23rd int. conference on water jetting, Seattle, USA
Prisco U, D'Onofrio MC (2008) Three-dimensional CFD simulation of two-phase flow inside the abrasive water jet cutting head. Int J Comp Meth Eng Sci Mech 9(5):300–319
Ahmed DH, Siores E, Naser J, Chen FL (2001). Numerical simulation of abrasive water jet for different taper inlet angles, 14th Australasian fluid mech. conference, 645–648
Haghbin N, Ahmadzadeh F, Spelt JK, Papini M (2015) Effect of entrained air in abrasive water jet micro-machining: reduction of channel width and waviness using slurry entrainment. Wear 344-345:99–109
Yerramareddy S, Bahadur S (1991) Effect of operational variables, microstructure and mechanical properties on the erosion of Ti-6Al-4V. Wear 142(2):253–263
Sookhak Lari MR, Papini M (2016) Inverse methods to determine scan velocity required to gradient etch three-dimensional textured features using abrasive jet micromachining: part I—modelling. Precis Eng 45:272–284
ANSYS fluent 15.0 theory guide. ANSYS, Inc., (2015, Canonsburg, PA, USA
Fowler G, Pashby IR, Shipway PH (2009) The effect of particle hardness and shape when abrasive water jet milling titanium alloy Ti6Al4V. Wear 266(7–8):613–620
Schwartzentruber J, Papini M (2014) Abrasive waterjet micro-piercing of borosilicate glass. J Mater Process Technol 219:143–154
Wang J (2009) Particle velocity models for ultra-high pressure abrasive waterjets. J Mater Process Technol 209(9):4573–4577
White F (2011). Fluid mechanics (seventh edition). McGraw Hill
Sheldon GL, Kanhere A (1972) An investigation of impingement erosion using single particles. Wear 21:195–209
Kowsari K, Nouraei H, James DF, Spelt JK, Papini M (2014) Abrasive slurry jet micro-machining of holes in brittle and ductile materials. J Mater Process Technol 214(9):1909–1920
Haghbin N, Spelt JK, Papini M (2015) Abrasive waterjet micro-machining of channels in metals: comparison between machining in air and submerged in water. Int J Mach Tools Manuf 88:108–117
Hutchings IM (1981) A model for the erosion of metals by spherical particles at normal incidence. Wear 70(3):269–281
Nouraei H, Kowsari K, Papini M, Spelt JK (2015) Operating parameters to minimize feature size in abrasive slurry jet micro-machining. Precis Eng 2016(44):109–123
Acknowledgements
The authors acknowledge the financial support from the Natural Sciences and Engineering Research Council of Canada (NSERC) and the Canada Research Chairs Program. CFD computations were performed on the general purpose cluster (GPC) supercomputer at the SciNet HPC Consortium. SciNet is funded by the Canada Foundation for Innovation under the auspices of Compute Canada, the Government of Ontario, Ontario Research Fund—Research Excellence, and the University of Toronto.
Author information
Authors and Affiliations
Corresponding authors
Rights and permissions
About this article
Cite this article
Teti, M., Spelt, J.K. & Papini, M. Jet properties and mixing chamber flow in a high-pressure abrasive slurry jet: part II—machining rates and CFD modeling. Int J Adv Manuf Technol 101, 3021–3034 (2019). https://doi.org/10.1007/s00170-018-3041-3
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-3041-3