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An investigation into the abrasive waterjet milling circular pocket on titanium alloy

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Abstract

This paper presents an experimental study on abrasive waterjet (AWJ) milling circular pockets of the titanium alloy Ti6Al4V workpieces. A material removal model is firstly deduced to understand the erosion process of AWJ milling. Experiments are conducted to research the effects of the processing parameters (water pressure, abrasive flow rate, traverse speed, and stand-off distance) on the performance of the milled circular pockets of Ti6Al4V workpieces. Dominating parameters and their interactive effects on the milling depth and roughness of milled surfaces are presented based on Box-Behnken design method. A comparative analysis is taken for the average milling depth, which is dominated by several dimensionless variables that control the final performance involved in the milled circular pocket. Subsequently, through quantitative assessments by the experiments, predictions by the material removal model are in good agreement with experimental results with an average deviation of 3.5%.

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Abbreviations

C :

Average depth coefficient

C d :

Discharge coefficient

C e :

Material property constant

d c :

Diameter of milling circular pocket (mm)

d 0 :

Diameter of focusing nozzle (mm)

E :

Modulus of elasticity (MPa)

h av :

Average milling depth (mm)

h 1 :

Relative height of orifice entrance (mm)

h 2 :

Relative height of orifice exit (mm)

H V :

Vickers hardness (MPa)

K e :

Effective abrasive impact coefficient

L :

Milling path length

m a :

Abrasive flow rate (g/min)

m p :

Mass of an abrasive particle (g)

m j :

Mass flow rate of waterjet (g/min)

P :

Water pressure (MPa)

P 0 :

Standard atmospheric pressure (MPa)

SOD :

Stand-off distance (mm)

s :

Step-over distance

t :

Unit of time

TS :

Traverse speed (mm/min)

ν 1 :

Waterjet velocity before orifice (m/s)

ν j :

High-pressure water outlet velocity (m/s)

ν p :

Abrasive velocity (m/s)

ν p0 :

Velocity of abrasives before ejection from the focusing nozzle (m/s)

V O :

Over material Removal Rate (mm3)

∆V :

Material removal rate of a single abrasive (mm3)

σ f :

Material flow stress (MPa)

ρ 0 :

Water density at ambient water pressure (MPa)

ρ 1 :

Water density at high pressure (MPa)

η t :

Momentum transfer efficiency

μ f :

Water orifice friction coefficient

α i :

Exponential constant

λ i :

Exponential constant

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Funding

The authors would like to acknowledge fundings from National Key Research and Development Project (2018YFB2001603 ), Joint Fund of MOE and GAD (6141A02022133), NSFC-Liaoning Joint Fund (U1708256, U1908232), and Fundamental Research Funds for the Central Universities (DUT18GF104).

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Authors and Affiliations

  1. School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    Yemin Yuan, Jianfeng Chen, Hang Gao & Xuanping Wang

  2. Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian, China

    Hang Gao & Xuanping Wang

Authors
  1. Yemin Yuan
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  2. Jianfeng Chen
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  4. Xuanping Wang
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Correspondence to Xuanping Wang.

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Yuan, Y., Chen, J., Gao, H. et al. An investigation into the abrasive waterjet milling circular pocket on titanium alloy. Int J Adv Manuf Technol 107, 4503–4515 (2020). https://doi.org/10.1007/s00170-020-05294-x

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