CHARACTERISATION OF SURFACE TOPOGRAPHY FOR ABRASIVE WATERJET TECHNOLOGY AND ITS CONTROL

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1 Alexander KIRÁLY Jan VALÍČEK Milena KUŠNEROVÁ Marta HARNIČÁROVÁ Mustafa YAGIMLI Hakan TOZAN CHARACTERISATION OF SURFACE TOPOGRAPHY FOR ABRASIVE WATERJET TECHNOLOGY AND ITS CONTROL

2 Yayın No : 3183 Teknik Dizisi : Baskı - Aralık İSTANBUL ISBN Copyright Bu kitabın bu basısı için Türkiye deki yayın hakları BETA Basım Yayım Dağıtım A.Ş. ye aittir. Her hakkı saklıdır. Hiçbir bölümü ve paragrafı kısmen veya tamamen ya da özet halinde, fotokopi, faksimile veya başka herhangi bir şekilde çoğaltılamaz, dağıtılamaz. Normal ölçüyü aşan iktibaslar yapılamaz. Normal ve kanunî iktibaslarda kaynak gösterilmesi zorunludur. Dizgi : B e t a B a s ı m A. Ş. Bask -Cilt : Birlik Fotokopi Baskı Ozalit ve Büro Malz. San. Tic. Ltd. Şti. Yıldız Mah. Çırağan Cad. No: 5 1 Nolu Mağaza Beşiktaş/İST. Tel: (0212) (Sertifika No: 20179) Kapak Tasarım : Gülgonca Çarpık Beta Basım Yayım Dağıtım A.Ş. (Sertifika No: 16136) Narlıbahçe Sok. Damga Binası No: 11 Cağaloğlu -İSTANBUL Tel : (0-212) Fax: (0-212)

3 In the submitted scientific monograph, the developed method of optical detection and analysis of geometric parameters of the topography of abrasive waterjet cut wall surfaces for proposing a method of automatic quality check and control is presented. On the basis of analysis and interpretation of data obtained from the surface, a topography function Ra d, which is necessary to be known for the subsequent prediction and control of abrasive waterjet cutting technology, is derived. In the framework of interpretation of measured values, relations among these parameters are systematically analysed and physico-mechanical and distributional principles governing these parameter are formulated newly. The generalization of these principles is done by means of analytically, correlationally, regressionally and empirically derived equations with a graphical representation of distribution of their functions. Based on a number of new findings beneficial to the clarification of cutting mechanism, a classification of materials according to classes of cuttability of materials using an abrasive waterjet T cut is proposed in the submitted work. Here, a design of a closed loop control system of influencing the technology of abrasive waterjet cutting of materials depending on the continuous measurement of sound pressure level L aeq is given. By the closed loop the control of traverse speed of the cutting head v p and thus also the control of final roughness of the cut wall Ra d, which is in functional relation to the traverse speed v p, is ensured. To this effect, a control loop is designed and a suitable PI controller is selected. The design is verified in Matlab-Simulink simulation environment. Results meet theoretical assumptions and requirements of present technological practice in the area of final surface topography. Acknowledgement This monograph has been elaborated in the framework of the IT4Innovations Centre of Excellence project, reg. no. CZ.1.05/1.1.00/ supported by Operational Programme 'Research and Development for Innovations' funded by Structural Funds of the European Union and state budget of the Czech Republic, the project RMTVC No. CZ.1.05/2.1.00/ , the project Institute of Clean Technologies for Mining and Utilization of Raw Materials for Energy Use, Reg. No. CZ.1.05/2.1.00/ and SGS project reg. no. SP2014/114. Reviewers: Prof. RNDr. Petr Wyslych, CSc Assoc. Prof. Ing. Krzysztof Rokosz, Ph.D. Asst. Prof. Veysel Alankaya, Ph.D. 3

4 Contents LIST OF USED SYMBOLS FOR QUANTITIES MEASURED LIST OF ABBREVIATIONS AND SYMBOLS USED GENERALLY INTRODUCTION METHODS OF MATERIAL CUTTING LIQUID JET CUTTING OF MATERIALS DIVISION OF LIQUID JETS CHARACTERISTICS OF AWJ TECHNOLOGY Tool Creation Liquid Liquid Filtration and Treatment Compression Pressure Liquid Distribution Water Nozzle Abrasive Jet Generation Abrasive Material Focusing Tube Action of the Tool Jet Propagation in Environment between the Nozzle and the Material Interaction with the Material Jet Attenuation TECHNOLOGY FACTORS CHARACTERISTICS OF DIRECT AND INDIRECT FACTORS SIGNIFICANCE OF INFLUENCE OF AWJ FACTORS

5 4 CURRENT SITUATION IN ABRASIVE WATERJET CUTTING OF MATERIALS SUMMARY OF KNOWLEDGE OF CUT WALL GENERATION CURRENT LEVEL OF THEORETICAL SOLUTIONS FOR PARAMETERS OF CUT STATE OF PRESENT THEORETICAL SOLUTIONS FOR PARAMETERS OF CUT GENERATED BY ABRASIVE WATERJET EVALUATION OF EXISTING KNOWLEDGE FROM THE POINT OF VIEW OF CURRENT NEEDS OF ABRASIVE WATERJET CUTTING METHODS OF SURFACE TOPOGRAPHY EVALUATION DIVISION OF METHODS FOR SURFACE TOPOGRAPHY EVALUATION Mechanical method Optical methods Other methods STANDARDIZED PARAMETERS OF SURFACE PROFILE THEORETICAL BACKGROUND AND DESIGN OF SOLUTION FOR CURRENT SITUATION IMPLEMENTATION OF APPROACH ITSELF CUT WALL GEOMETRY AND ITS IMPORTANCE TO ANALYSIS OF ABRASIVE WATERJET PROCESS ANALYSIS OF MECHANISM FROM THE POINT OF VIEW OF GENERATION OF CUT WALL TOPOGRAPHY OPTICAL MEASUREMENT OF TOPOGRAPHY FUNCTION IN REGIONS OF SURFACE ROUGHNESS AND WAVINESS Light scattering due to microroughness Shadow method Fundamental principle of measurement and optical diagram of shadow method Theoretical basis and method of quantitative interpretation of measurement results MEASUREMENT OF AWJ GENERATED SURFACE TOPOGRAPHY BY MEANS OF OPTICAL PROFILOMETER Principle of optical profilometer microprof frt

6 6.5.2 Analysis of data obtained from measurements by the instrument microprof FRT SAMPLE PREPARATION AND ANALYSIS OF MEASUREMENT OF SURFACE TOPOGRAPHY ANALYSIS OF EXPERIMENTAL DATA OBTAINED BY SHADOW METHOD FINDINGS AND CONCLUSIONS DRAWN FROM EXPERIMENTAL RESULTS SURFACE TOPOGRAPHY FUNCTION DESIGNED MAIN GEOMETRIC PARAMETERS OF ABRASIVE WATERJET CUT SURFACES INTERRELATIONS AMONG GEOMETRIC PARAMETERS SHAPE OF TOPOGRAPHY FUNCTION USE OF A TOPOGRAPHY FUNCTION FOR THE SETTING OF THE ABRASIVE WATERJET CUTTING TECHNOLOGY DESIGN OF TECHNOLOGICAL PROCESS CONTROL MEASUREMENT OF SOUND PRESSURE LEVEL EVALUATION OF INFLUENCE OF FACTORS ON THE SOUND PRESSURE LEVEL RELATION BETWEEN THE SOUND PRESSURE LEVEL AND VIBRATIONS INPUT SIGNAL ANALYSIS, CONTROL FUNCTION AND CONTROL PRINCIPLE PROPOSAL FOR METHOD OF CONTROL LOOP DESIGN DESIGN OF CONTROLLER FOR SYSTEMS WITH TRANSPORT DELAY SYSTEM SIMULATION CONTROL LOOP STABILITY DESIGN OF CONTROLLER FOR SYSTEMS WITHOUT TRANSPORT DELAY SYSTEM SIMULATION SIMULATION OF SURFACE IN THE FRAMEWORK OF MECHANICAL INTEGRITY OF MATERIAL BEING CUT COMPARISON OF DESIGNED CONTROLLERS CONCLUSION REFERENCES

7 LIST OF USED SYMBOLS FOR QUANTITIES MEASURED â diffraction slit length [mm] a o abrasive particle size [mm] b thickness of material [mm] c h distribution function of values (C h1 C h22 ) in [1] relation to depth h C h quantitative criterion for surface topography [1] evaluation C 1 coefficient for the kind of material being cut [1] C f coefficient of resistance of material wall [1] C k coefficient of characteristic speed [1] d a focusing tube diameter [mm] d aopt optimized diameter of tube [mm] d f focusing tube diameter [mm] d fopt optimized focusing tube diameter [mm] d o orifice diameter [mm] d p particle diameter [mm] d vopt optimized water orifice diameter [mm] D E exit jet diameter [mm] D H head jet diameter [mm] D P jet diameter at the bottom [mm] E z Young s modulus of grain [MPa] E mat Young s modulus of material [MPa] E alt altered Young s modulus of material [MPa] E alti instataneous value of altered Young s modulus [MPa] of material f spatial frequency [mm -1 ] F cut cutting force [N] G shear modulus [MPa] h total depth of cut [mm] h c cutting zone [mm] 7

8 h d deformation zone [mm] h j unit depth of cut [mm] h lim limit depth of cut for the material being [mm] machined h o neutral plane [mm] h S mean value of function of cut depth [mm] h vz sample height (8 mm) [mm] H a abrasive material hardness [N mm -2 ] I o machinability index [1] I ( ) distributed light intensity [mv] I ( ) scattered light intensity in direction of [mv] observation I (u S ) light intensity in plane of observation [mv] I (ζ S ) light intensity in direction of observation [mv] k S instrument-dependent constant [1] k th unit constant [mm] k vjp auxiliary unit coefficient [1] K abr technology coefficient for abrasive effects [1] K cut coefficient of cuttability of material [mm] K cutj unit cuttability of material [mm] K cuto cuttability of material in neutral plane [mm] K dadv optimized ratio focusing tube / water orifice [1] diameter K p technology coefficient for effects of pressure in [1] front of nozzle K reg control coefficient [db μm -1 ] K tech complex technology coefficient [1] K vp technology coefficient for effects of cutting [1] head traverse speed v P K vpm technology coefficient for effects of v p on mechanical alteration [1] 8

9 K vpra technology coefficient for effects of v p on [1] roughness Ra l a focusing tube length [mm] l c coherence length [mm] l n evaluation length [mm] l p measurement length [mm] l r basic length [mm] L nozzle-material surface distance [mm] L aeq sound pressure level [db] L aeqc overall sound pressure level [db] L aeqopto optimum sound pressure level [db] L aeqp value of L aeq for background of plant and pump [db] L aeqreg controlled optimum sound pressure [db] L aeqvibr vibration level [db] L aeqj unit sound pressure level [db] L aeqrad0 L aeq related to topography function Ra d in neutral plane [db] L aeqrarad0 L aeq related to radial surface roughness Ra d in [db] neutral plane L aeqrad L aeq related to topography function Ra d [db] L aeqrarad L aeq related to radial surface roughness Ra rad [db] m a abrasive mass flow rate [kg min -1 ] m aopt optimized abrasive mass flow rate [kg min -1 ] n p number of passes [1] P liquid pressure [Pa] p opt optimized pump pressure [Pa] p P pressure due to the pump [Pa] p S plane-observation point distance in direction of wave inverse function [mm] r yy standardized autocorrelation function [1] Ra average surface roughness profile parameter [ m] Ra d detected topography function [ m] 9

10 R ado detected topography function at the neutral [ m] plane Ra dreg controlled surface roughness Ra d [μm] Ra j unit surface roughness [μm] Ra o surface roughness in neutral plane of cut [μm] Ra rad radial surface roughness [μm] Ra radreg controlled radial surface roughness Ra rad [μm] RMS Root Mean Square, RMS value of signal of light [a.u.] intensity Rq root mean square deviation of profile [μm] Rz maximum height of profile irregularity [μm] S p cutting head traverse direction [ ] Sm mean spacing of height amplitudes [mm] t simulation time [s] T cut cuttability class [1] v a speed of motion of abrasive particles [m s -1 ] v e critical speed of motion of abrasive particles [m s -1 ] v p traverse speed of cutting head [m s -1 ] v pj unit traverse speed [m s -1 ] v popt optimum traverse speed of cutting head in [m s -1 ] various materials v preg controlled traverse speed of cutting head [m s -1 ] v UZ, L longitudinal ultrasonic wave speed in material [m s -1 ] v pregrad controlled traverse speed related to Ra d [m s -1 ] v pregrarad controlled traverse speed related to Ra rad [m s -1 ] x H sound meter-nozzle distance [mm] x z stand-off distance [mm] Y ret retardation of cut trace, curvature of AWJ trace [mm] Y retgen general retardation of cut trace at cut bottom [mm] Y reto retardation in neutral plane [mm] Zp maximum peak height within basic length l r [mm] 10

11 Zv maximum valley depth within basic length l r [mm] c critical angle of particle impingement at depth h c [ ] d angle of abrasive particle impingement [ ] angle of light impingement [ ] d set angle under which AWJ impinges on sample [ ] γ skewness [1] Δa mean angle of irregularity slope [ ] δ angle of deviation of cut trace [ ] gen general angle of curvature [ ] i instantaneous angle of curvature [ ] ε relative longitudinal plastic elongation [1] ξ surface topography function [mm] ξ S spatial frequency associated with spatial [mm -1 ] coordinate u S observation angle [ ] d angle of particle impingement [ ] light wavelength [nm] S surface topography irregularity wavelength [mm] μ Poisson ratio [1] ρ material density [kg m -3 ] ρ p abrasive material density [kg m -3 ] σ D compressive strength [MPa] def flow stress in cut [MPa] σ j unit stress [MPa] σ kl yield point of material being cut [MPa] σ pr compensating stress [MPa] σ pri instataneuos of compensating stress [MPa] σ pro compensating stress in neutral plane [MPa] σ T tensile strength [MPa] diffraction angle [ ] p action angle [ ] 11

12 LIST OF ABBREVIATIONS AND SYMBOLS USED GENERALLY A A( S ) A*( S ) AFM A I A R (x) ASJ AS CR AWJ B C CCD d In d Ot D e ECM EDM FFT 12 initiation zone complex amplitude of light wave complex conjugate amplitude of light wave Atomic Force Microscopy, interatomic forces incident wave amplitude complex amplitude of light wave just after reflection Abrasive Slurry Jet, abrasive suspension jet Academy of Sciences of the Czech Republic Abrasive Water Jet smooth zone transition zone Charge Coupled Device, charge coupled element disturbance at the input disturbance at the output striated zone deviation of output value from desired value w Electro-Chemical Machining Electrical Discharge Machining, electro-erosion machining Fast Fourier Transform g (x, y) functional values of waviness, partial function w(x, y) G 0 (s) G M (s) G Mč (s) G Pr (s) G R (s) G S (s) G TP (s) transfer of the inverse function of open loop transfer of the inverse function of electric motor transfer of the inverse function of measuring element transfer of the inverse function of gear transfer of the inverse function of controller transfer of the inverse function of system transfer of the image of technological process of material cutting

13 h (x, y) functional values of microroughness, partial function w(x, y) H( S ) CHM i I * k p k M k Pr K R LBM MFM M 0 (s) n S N 0 (s) N w (s) P P (φ) PI PBM r R R R S RTG s S S ( ) SEM STM Fourier transform of function h(x) Chemical Machining sequence number of profile point, instantaneous values integral controller controller gain coefficient electric motor constant gear constant substitution constant Laser Beam Machining Magnetic Force Microscopy polynomial of numerator of open loop transfer function coefficient of surface texture characteristic polynomial of open loop standard polynomial of closed loop without T d basic surface profile density function proportional-integral controller Plasma Beam Machining mean surface refractivity controller surface roughness profile surface reflectance diffraction method using X-radiation complex variable controlled system function of impingement angle, shadow function Scanning Electron Microscopy Scanning Tunnelling Microscopy, tunnel effect 13

14 T T d * T I TIS T M T Pr sampling period transport delay controller integration constant Total Integrated Scattering electric motor time constant gear time constant T w u u S U (s) USM V p (s) w w (x, y) W W(β) WJ y y(x) y(x i ) Y (s) 14 time constant of closed loop without T d manipulated variable spatial coordinate image of manipulated variable Ultrasonic Machining image of transverse speed of cutting head desired value of controlled quantity y total amplitude of height irregularities surface waviness profile reflection ratio as function of impingement angle Water Jet, pure waterjet output variable function describing the profile coordinate of n points of surface profile image of output variable α, β coefficients of required model method ξ w x (x) coefficient of relative damping of control loop root mean square deviation gradient root mean square deviation mean value of angular distribution of light intensity phase of light wave due to surface roughness s inverse function of angular speed of rotor κ overshoot

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