Margini di miglioramento tecnologico: innovazioni dalla ricerca 13 Maggio Massimiliano Annoni
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1 Margini di miglioramento tecnologico: innovazioni dalla ricerca 13 Maggio 2010 Massimiliano Annoni
2 New trends: high precision WJ cutting AWJs: diameter > 300 micron FAWs: 50 < diameter < 300 micron MAWs: diameter < 50 microns Miller, D. S. (2006) Miniature components cut on Finecut waterjet fine abrasive (FAW) machining centre ( Waterjets: evolving from Macro to Micro, cutting smaller, faster and deeper, Manufacfturing Engineering, SME, November 2009 Vol. 143 No. 5 Politecnico di Milano - M. Annoni back 14
3 High precision WJ cutting (tollerance = 0.01 mm on the workpiece) Improvement of the current components: Orifice Mixing chamber Focuser By means of: CFD simulations Experimentations Fluid-dynamic validation of simulations Cutting performance Politecnico di Milano - M. Annoni back 15
4 CFD simulations Constricted water jets (transient state) Cone: 60 Aspect ratio = 1.5 Diameter = 0.15 mm P = 300 MPa M. Annoni, M. Monno, Effect of water jet orifice geometry on jet behaviour and cutting capability, Ke y Engineering Materials, Vol. 344 (2007), pp , ISSN Politecnico di Milano - M. Annoni back 16
5 CFD simulations Reattachment of water jets (transient state) Cone: 30 Aspect ratio = 1 Diameter = 0.25 mm P = 300 MPa A.T. Basha, M Annoni, M. Monno, Numerical Simulation Of The Formation And Reatachment Length Of WaterJets For Different Orifice Geometries WJTA confrence. Aug. 2009,USA Politecnico di Milano - M. Annoni back 17
6 CFD simulations Jet and droplets formation In collaboration with: Politecnico di Milano - M. Annoni back 18
7 High speed camera observations Camera and Settings SensiCam by PCO ( 1280x1024 pixels maximum Frame rate 1 Hz Delay flash-exposure 6 microseconds Exposure time microsecond depending on nozzle diameter and configuration Zoom: Focal 80, f/a 4 (completely open) Distance water jet - camera body 136 cm Resolution 11.4 pixel/mm (11.5 the preliminaris) Image size 1280x576 pixels (x544 on the scale) Flash position: Preliminari 2x Flash high, side , distance 11 cm: And 2x Flash high, side , distance 11 cm: Politecnico di Milano - M. Annoni back 19
8 High speed camera observations 50 MPa 160 MPa 100 MPa 220 MPa d = 0,080 mm Politecnico di Milano - M. Annoni back 20
9 High speed camera observations spray width mm P220 P160 P100 P mm image length 0785 Politecnico di Milano - M. Annoni back 21
10 Water jet observations Air effect Vahedi Tafreshi et al. (2004)) Nozzle Exit Spray Onset Breakup Length Abrasive A.H. Osman et al. (2003) Politecnico di Milano - M. Annoni back 22
11 Laser Doppler Velocimetry WATER JET VELOCITY AVAILABLE POWER 1cin 1 P 2 ρ1v 1 = 2 Q V 1 SYSTEM EFFICIENCY CUTTING HEAD EFFICIENCY η = η N = p1q P el 1 1 V 2 1 V s = h h 0 0 h h 1 1s ORIFICE EFFICIENCY C c, C v, C d M. Annoni, L. Cristaldi, M. Norgia, C. Svelto, Efficiency Measurement of Water Jet Orifices by a Novel Electrooptical Technique, IEEE Transactions on Instrumentation and Measurement, Vol. 57, No. 1, January 2008, pp Politecnico di Milano - M. Annoni back 23
12 Laser Doppler Velocimetry Z Y X λ = 780 nm L = 2581 mm s = 35 mm p = 100 MPa d or = 0,15 mm sod = 60 mm Annoni, M., Cristaldi, L., Norgia, M., Svelto, C., Measurement of Water Jet Velocity Distribution Using Laser Velocimetry, IEEE Trans. on Instrumentation and Measurement, Vol. 57, No. 8, August 2008, pp D t Measurement uncertainty of water jet velocity acquired by a laser Doppler velocimeter Massimiliano Annoni, 9 Convegno AITEM, 2009 F Politecnico di Milano - M. Annoni back 24
13 Laser Doppler Velocimetry V = D F Politecnico di Milano - M. Annoni back 25
14 Laser Doppler Velocimetry Experimental conditions (B orifices) Orifice characterization C d ψ Mean St. Dev. Mean St. Dev. Mean St. Dev MPa 0.67 < < < MPa 0.68 < < < 0.01 C v C c Experimental conditions (B broken orifices) Mean C d ψ Mean C v Mean C c MPa MPa Good conditions Broken orifice M. Annoni, M. Faifer, M. Norgia, Orifice Coefficients Evaluation for Water Jet Applications, 16th IMEKO TC4 Symposium Exploring New Frontiers of Instrumentation and Methods for Electrical and Electronic Measurements, September 22-24, 2008, Florence, Italy, pp Politecnico di Milano - M. Annoni back 26
15 Static pressure measurements High pressure water Mixing chamber Air control valve Air suction port p1 p7 Mixing tube Pressure taps p2 p3 Custom made LabVIEW program p5 p6 p4 Politecnico di Milano - M. Annoni back 27
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