Search Results (134)

The mixing valve is a key component of an ultra-high-pressure premixed abrasive waterjet system, in which the abrasive–water mixing uniformity plays a decisive role in determining the erosion and cutting performance of the jet. The geometric parameters of the mixing chamber inside the valve are therefore critical factors affecting this uniformity. In this study, the liquid–solid two-phase flow within the mixing chamber was numerically investigated using the Eulerian k–ε turbulence model coupled with the Fluent–Rocky DEM approach. Single-factor simulations were first conducted to identify the effective ranges of key structural parameters influencing the mixing performance. Subsequently, a response surface model was established to describe the relationship between the mixing efficiency (ME) and four critical chamber parameters, namely the throat diameter (TD), throat length (TL), abrasive inlet pipe diameter (AD), and the distance between the throat exit and the abrasive inlet pipe center (TE). Based on this model, the optimal structural parameters of the mixing chamber were determined. The results indicate that when TD = 4 mm, TL = 12 mm, AD = 10 mm, and TE = 7 mm, the simulated ME reaches 34.40% ± 0.49%, which is in close agreement with the predicted value of 34.57%. Experimental validation conducted on a premixed abrasive waterjet test rig shows that the mean absolute relative error between the simulated and measured ME values is 7.54%, which is below the 10% threshold, confirming the reliability and accuracy of the numerical model. Full article

Additive manufacturing by Fused Filament Fabrication (FFF) enables the fabrication of complex polymer components, although limitations in surface quality and dimensional accuracy often require post-processing. Abrasive water jet machining (AWJM) is a non-thermal technique suitable for improving surface integrity in polymers and composites without inducing thermal damage. This study investigates the AWJM performance on FFF-printed polylactic acid (PLA) and carbon-fiber-reinforced PLA (PLA–CF), focusing on the influence of water pressure (WP), traverse feed rate (TFR), and abrasive mass flow rate (AMFR). A full factorial design was implemented, and surface integrity was evaluated through surface roughness (Ra) and kerf taper (T), considering their variation across characteristic cutting regions: initial damage region (IDR), smooth cutting region (SCR), and rough cutting region (RCR). Results show that WP and TFR are the dominant parameters, while AMFR has a limited effect within the studied range. The SCR exhibits the lowest roughness, whereas the RCR shows significant degradation due to energy loss. Both materials present similar behavior, with only minor improvements in PLA–CF. ANOVA confirms that process parameters have a stronger influence than material type, providing useful criteria for AWJM optimization in FFF polymers. Full article

Abrasive waterjet machining (AWJM) is widely used for cutting aerospace aluminum alloys, but exit-side defects associated with jet lag can degrade surface integrity and dimensional accuracy. This work investigates the influence of water pressure, abrasive mass flow rate, and traverse feed rate on the formation of jet-lag defects at the exit side of cuts in UNS A92024 aluminum alloy plates of 10 mm thickness. A full factorial 3³ experimental design was implemented to manufacture 27 square samples (20 × 20 mm), which were subsequently characterized by optical microscopy at 20× magnification. The semicircular jet-lag defects were quantified using Imaging processing techniques to determine their projected area, and the resulting data were analyzed with multifactor ANOVA and multiple linear regression. The results show that traverse feed rate and water pressure have a statistically significant effect on defect area, with traverse feed rate being the most influential factor, whereas the abrasive mass flow rate plays a secondary role within the investigated range. Combinations of high water pressure and low traverse feed rate led to cleaner cuts with reduced exit-side damage, and contour plots allowed the identification of operational windows that minimize defect formation. The proposed methodology provides a systematic framework for characterizing jet-lag defects in AWJM and can be extended to other alloys, thicknesses, and advanced characterization techniques to support process optimization in industrial applications. Full article

The surface characteristics of zirconia may influence both soft tissue response and bacterial colonization. This study evaluated the surface roughness and water contact angle of zirconia fabricated by additive manufacturing (material jetting, NPJ) and subtractive manufacturing (milling), and investigated human gingival fibroblast (HGF-1) viability and Streptococcus mutans (S. mutans) (ATCC 25175) adherence on these surfaces, as well as the possible correlation between roughness and bacterial adhesion. Sixty-four zirconia specimens (1 × 1 × 0.1 cm) were fabricated (n = 32 per group), sintered, and standardized by abrasive polishing. Surface roughness and contact angle were measured. Cell viability was assessed using an MTT assay at 24, 48, and 72 h. Bacterial adhesion was quantified after 24 and 48 h of incubation. Data were analyzed using two-way ANOVA, independent t-tests, and Pearson correlation (α = 0.05). No significant differences in HGF-1 viability were observed at 24 and 48 h; however, at 72 h, subtractively manufactured zirconia demonstrated higher cell viability than additively manufactured specimens (p < 0.001). S. mutans adhesion was significantly greater on additively manufactured zirconia at 24 h (p = 0.002), with no significant difference at 48 h. Manufacturing technique influenced surface properties and early bacterial adhesion. Both materials exhibited acceptable biocompatibility within the tested conditions. Full article

This paper investigates the AWJ machinability of Hibiscus Rosa-Sinensis/carbon nanotube (CNT) fiber/epoxy-based hybrid composites by analyzing key machinability metrics such as kerf width (KW), material removal rate (MRR), and surface roughness (Ra). Various process parameters including CNT weight percentage, CNT diameter, stand-off distance, and traverse speed have been varied to optimize the machining performance. Experimental analysis suggested that increasing the CNT weight percentage significantly enhanced material hardness, thereby reducing both the MRR and surface roughness. Moreover, adjusting the stand-off distance and traverse speed further improved the machinability of the composite. ANOVA results highlighted that CNT weight percentage was a significant factor, accounting for 94.17% of the variation in MRR and 93.72% of the variation in surface finish, while the stand-off distance influenced 87.03% of the variation in kerf width. Additionally, response surface methodology (RSM) was utilized to develop predictive models that estimated KW, MRR, and Ra with error rates of 2.95%, 2.23%, and 5.65%, respectively. These insights offer a valuable framework for tailoring the AWJ process to achieve optimal machining outcomes in HRS/CNT/epoxy composite materials Full article

Residual stresses are a persistent challenge in the additive manufacturing of composite parts by FFF (Fused Filament Fabrication) and can impair dimensional accuracy and mechanical performance. This article evaluates reflection photoelasticity (PhotoStress) as a full-field optical technique to visualize and compare residual-stress relaxation in ASA (Acrylonitrile Styrene Acrylate) reinforced with aramid fibers. The approach combines a controlled AWJ (Abrasive Water Jet) relief cut to induce local stress release with subsequent optical recording of isochromatic fringe fields using a reflection polariscope. Samples with thicknesses of 2–10 mm were manufactured and evaluated in two conditions: non-annealed and after annealing (80 °C/5 h). Under identical optical settings, no discernible isochromatic fringes were detected for 2–6 mm (Nmaxlobal < 0.60 in both conditions), whereas resolvable fringe patterns were observed for 8–10 mm. For 8 mm, the response was localized near the relief cut, with Nmax,global = 1.0 in the non-annealed condition and Nmax,global < 0.60 after annealing. For 10 mm, the response was more spatially extensive, and annealing reduced the global maximum from Nmax,global = 1.2 to 0.9. Taken together, these results demonstrate that reflection photoelasticity supports comparative full-field visualization of residual-stress relaxation in FFF composite specimens under fixed measurement conditions. In addition, an AWJ relief cut constitutes a practical and repeatable stress-release feature with limited additional thermal influence in the present configuration. Full article

Abrasive water jet machining (AWJM) is a non-traditional machining process that is increasingly employed for shaping hard-to-machine materials, particularly titanium (Ti)-based alloys such as Ti-6Al-4V. Owing to its non-thermal nature, AWJM enables effective material removal while minimising metallurgical damage and preserving subsurface integrity. The process performance is governed by several interacting parameters, including jet pressure, abrasive type and flow rate, nozzle traverse speed, stand-off distance, jet incident angle, and nozzle design. These parameters collectively influence key output responses such as the material removal rate (MRR), surface roughness, kerf geometry, and subsurface quality. The existing studies consistently report that the jet pressure and abrasive flow rate are directly proportional to MRR, whereas the nozzle traverse speed and stand-off distance exhibit inverse relationships. Nozzle geometry plays a critical role in jet acceleration and abrasive entrainment through the Venturi effect, thereby affecting the cutting efficiency and surface finish. Optimisation studies based on the design of the experiments identify jet pressure and traverse speed as the most significant parameters controlling the surface quality in the AWJM of titanium alloys. Recent research demonstrates the effectiveness of artificial neural networks (ANNs) for process modelling and optimisation of AWJM of Ti-6Al-4V, achieving high predictive accuracy with limited experimental data. This review highlights research gaps in artificial intelligence-based fatigue behaviour prediction, computational fluid dynamics analysis of nozzle wear mechanisms and jet behaviour, and the development of hybrid AWJM systems for enhanced machining performance. Full article

Deep-sea cages are highly susceptible to biofouling due to long-term seawater immersion, which promotes the attachment and growth of marine organisms on nets, significantly reducing fish survival. To address this issue, this study explores the use of low-pressure abrasive water jets (LPAWJs) for cage fouling removal through numerical simulation. Based on a Box-Behnken response surface design, nozzle inlet pressure X₁, nozzle outlet diameter X₂, and target distance X₃ were selected as optimization parameters. The peak jet impact force Z₁, stable jet impact force Z₂, peak abrasive water jet velocity Z₃, and peak abrasive particle velocity Z₄ were chosen as evaluation indicators to characterize the jet’s instantaneous impact ability, sustained action ability, and dynamic particle behavior. Using the entropy method, weights for each indicator were determined, and the jet’s overall removal capability was calculated. A regression model was developed by integrating numerical simulation with the response surface methodology (RSM), and the optimal parameter combination was identified as X₁ = 4.5 MPa, X₂ = 10 mm, and X₃ = 205.396 mm. Compared with the poorest experimental condition (Condition 1), the jet’s overall removal capability obtained under the optimal parameter combination increases by 101.35%. Experimental validation further confirms that the optimized parameters yield the best oyster-removal performance of the low-pressure abrasive jet, with the average removal rate improving by 100.55% relative to Condition 1. The methodology and results of this study provide a theoretical foundation and technical reference for the design and optimization of automated net-cleaning systems or net-cleaning robots equipped with low-pressure abrasive jets. By integrating the proposed model and operating parameters, future robotic systems will be able to predict and dynamically adjust jet conditions according to fouling characteristics, thereby improving the efficiency, cost-effectiveness, and sustainability of maintenance operations in marine aquaculture. Full article

Various materials may be machined using the abrasive water jet (AWJ) cutting method. Many control factors, such as abrasive flow, operating pressure, and traverse speed, influence the efficiency and surface quality of AWJ-cut components. The common distinguishing factor of process efficiency and quality is the angle of machining footprints (striation angle). This paper presents research results on the control parameters as a method of influencing the striation angle through the angle level of machining footprints to achieve high efficiency and quality, for example, the high-impact and abrasive-resistant steel. This will enable quality control of the AWJ cutting process by continuously measuring the jet deflection angle in an online mode and adjusting these parameters in real-time to maintain high efficiency and the required surface quality. The particular interest in utilizing this basis is the possibility of setting cutting parameters for new materials not included in the implemented model of the AWJ cutting machine. Full article

To investigate the flow-field characteristics of a submerged pre-mixed abrasive water jet impinging on a wall, a physical model of the conical–cylindrical nozzle and computation domain of a submerged pre-mixed abrasive-water-jet flow field were established. Based on the software of FLUENT 2022R2, numerical simulation of the solid–liquid two-phase flow characteristics of the submerged pre-mixed abrasive water jet impinging on a wall was conducted using the DPM particle trajectory model and the realizable $k–\epsilon$ turbulence model. The simulation results indicate that a “water cushion layer” forms when the submerged pre-mixed abrasive water jet impinges on a wall. Tilting the nozzle appropriately facilitates the rapid dispersion of water and abrasive particles, which is beneficial for cutting. The axial-jet velocity increases rapidly in the convergent section of the nozzle, continues to accelerate over a certain distance after entering the cylindrical section, reaches its maximum value inside the nozzle, and then decelerates to a steady value before exiting the nozzle. In addition, the standoff distance has minimal impact on the flow-field characteristic inside the nozzle. When impinging on a wall surface, rapid decay of axial-jet velocity generates significant stagnation pressure. The stagnation pressure decreases with increasing standoff distance for different standoff-distance models. Considering the effects of standoff distance on jet velocity and abrasive particle dynamics, a standoff distance of 5 mm is determined to be optimal for submerged pre-mixed abrasive-water-jet pipe-cutting operations. When the submergence depth is less than 100 m, its effect on the flow-field characteristics of a submerged pre-mixed abrasive water jet impinging on a wall surface remains minimal. For underwater oil pipelines operating at depths not exceeding 100 m, the influence of submergence depth can be disregarded during cutting operations. Full article

In the present experiment, the abrasive water jet machining parameters, such as water pressure, standoff distance, and traverse speed, are selected to study the effect of each parameter on the kerf taper angle and surface roughness during the machining of glass, jute, and carbon hybrid composite. The other machining parameters are kept constant. For each parameter, three levels are fixed on the basis of previous literature reviews. The Response Surface Methodology is used to design the required number of experiments and to optimize the machining parameters to obtain the minimum kerf taper angle and surface roughness. The levels selected for water pressure are 150, 220, and 250 MPa; traverse speeds are 20, 40, and 60 mm/min; and, similarly, stand-off distances are 2, 5, and 8 mm. Experimental results confirm that the parameter inversely affects both kerf angle and surface roughness. On the other hand, parameters traverse speed and stand-off distance, directly affecting both outputs. According to RSM optimization, to obtain the minimum kerf taper angle and surface roughness, we should fix the pressure at a higher level and other parameters at a lower level. For the considered range, the obtained minimum kerf angle and roughness values are 1.4982 radians and 2.0920 μm. Full article

The natural fiber-reinforced nanomaterial filler polymer matrix hybrid composite has superior applications in industrial and manufacturing fields due to its enhanced mechanical and machinability characteristics. However, in order to generate high-quality components, unconventional machining techniques, notably abrasive waterjet machining, have become more popular due to the inhomogeneity of composites, fiber pullout, greater surface roughness, and dimensional inaccuracy under traditional machining. Delamination typically refers to the separation that occurs along a plane parallel to the surface, such as the detachment of a coating from its underlying material or the separation between different layers within the coating itself. This paper investigates the AWJM characteristics of Hibiscus Rosa-Sinensis/Carbon nanotube/Epoxy (HRSCE)-based hybrid composite, focusing on delamination factors at entry, exit, and machining time. An L₂₇ orthogonal array was employed to optimize process parameters, revealing that DF-entry decreased with increasing CNT (wt.%), achieving its lowest values at 3 (wt.%) CNT and 2 mm stand-off distance due to enhanced composite toughness and precise jet focus. Conversely, DF-exit increased with higher CNT (wt.%), stand-off distance and traverse speed, attributed to the composite’s increased brittleness and reduced cutting efficiency. Machining time was predominantly influenced by CNT (wt.%) (92.4%), increasing with higher reinforcement levels due to enhanced material resistance. Response surface methodology models demonstrated high accuracy in predicting machining outcomes, with errors below 3%. Contour and surface plots identified optimal conditions for minimal delamination and machining time as 3 (wt.%) CNT, low stand-off distance (2 mm), and moderate traverse speed (200 mm/min). The SEM and optimal microscopy analysis confirmed that CNT reinforcement positively influenced fiber matrix interfacial integrity and reduced surface damage. Full article

The aim of this study was to analyze the effect of finishing methods on the surface quality of Ti-6Al-4V titanium alloy additively manufactured by selective laser melting. It was observed that among the finishing methods, water jet treatment did not produce significant changes, while the abrasive water jet proved effective in removing defects and smoothing the surface, especially at a pressure of 30 MPa. However, the risk of abrasive particle entrapment in the material was observed. Promising results were also obtained using the water–ice jet, which combines effective material removal with surface smoothing. The selection of the finishing method should be tailored to the application requirements. Further research will focus on optimization and the combination of techniques to improve the functional properties of titanium components. Full article

Cutting beech plywood using abrasive water jet (AWJ) technology represents a significant area of research due to increasing demands for precision, quality, and environmental sustainability in manufacturing processes within the woodworking industry. AWJ technology enables non-contact cutting of materials without causing thermal deformation or mechanical damage, which is crucial for preserving the structural integrity and mechanical properties of the plywood. This article investigates cutting beech plywood using technical methods using an abrasive water jet (AWJ) at 400 MPa pressure, with Australian garnet (80 MESH) as the abrasive material. It examines how abrasive mass flow rate, traverse speed, and material thickness affect AWJ lag, which in turn influences both cutting quality and accuracy. Measurements were conducted with power abrasive mass flow rates of 250, 350, and 450 g/min and traverse speeds of 0.2, 0.4, and 0.6 m/min. Results show that increasing the abrasive mass flow rate from 250 g/min to 350 g/min slightly decreased the AWJ cut width by 0.05 mm, while further increasing to 450 g/min caused a slight increase of 0.1 mm. Changes in traverse speed significantly influenced cut width; increasing the traverse speed from 0.2 m/min to 0.4 m/min widened the AWJ by 0.21 mm, while increasing it to 0.6 m/min caused a slight increase of 0.18 mm. For practical applications, it is recommended to use an abrasive mass flow rate of around 350 g/min combined with a traverse speed between 0.2 and 0.4 m/min when cutting beech plywood with AWJ. This balance minimizes jet lag and maintains high surface quality comparable to conventional milling. For thicker plywood, reducing the traverse speed closer to 0.2 m/min and slightly increasing the abrasive flow should ensure clean cuts without compromising surface integrity. Full article

Background: Compared to the conventional method of machining granite, abrasive water jet machining (AWJM) offers several benefits, including flexible cutting mechanisms and machine efficiency, among other possible advantages. The high-speed particles carried by water remove the materials, preventing heat damage and maintaining the granite’s structure. Methods: Three types of granite with different compressive strengths are investigated in terms of the effects of pump pressure (P), traverse speed (T), and abrasive mass flow (A) on the cutting depth. Results: The results of the study demonstrated that the coarse-grained granite negatively affected the penetration depth, while the fine-grained granite produced a higher cutting depth. The value of an optimal depth of penetration was also generated; for example, the optimum depth obtained for Black Galaxy Granite, M1 (32.27 mm), was achieved at P = 300 MPa, T = 100 mm/min, and A = 180.59 g/min. Conclusions: In terms of processing parameters, the maximum penetration depth can be achieved in granite with a higher compressive strength. Full article