<p>Abrasive waterjet (AWJ) machining is a complex, non-conventional machining process involving numerous input parameters including hydraulic, abrasive, mixing and cutting that must be accurately manipulated to guarantee precise cutting and quality. Currently, available models are empirical or require continuous calibration, or extensive experimental work. To reduce the calibration and experimental time required for accurate prediction of AWJ cutting, computational fluid dynamics (CFD) is being utilized to model the nozzle flow interaction; high pressure water is pushed through the orifice into the mixing chamber, pulling the abrasive into the flow and cohering in the focus tube. Initial research worked towards understanding the effect that input parameters - such as pressure, particle size and shape, focus tube length and volume fraction of air in fluid mixture - have on the velocity profile through the nozzle and upon exit to the atmosphere. Once understood, the CFD model can be utilized to vary mass-inlet, mixing head, orifice and focus tube dimensions to optimize velocity profile of abrasive material including magnitude and jet coherency. Primarily focused on pump pressure, which is limited by technology - an optimized AWJ nozzle will increase material removal rate and/or enhance cut quality without making changes to any other AWJM components.</p> <p>Utilizing the velocity output information from the CFD model, a depth of penetration erosion prediction model was generated. Based on methodology from Finnie, and modified by Hashish and ElTobgy, a multi-particle erosion model of an impacted work piece is developed. With an updated formulation for the specific cutting resistance of a work piece, dependent on particle velocity and nozzle traverse speed, the erosion prediction over the sixty-five different setups modelled and tested experimentally, reduced error on average 41.8%. Moreover, the development of this model created multi-layered surface plots, illustrating for quick reference, the erosion of a work piece for a given set of parameters albeit mass flow rate, pump pressure and traverse rate.</p> <p>Further, a database of quick reference guides, including variable input settings, nozzle types, garnet types and work piece materials can easily be developed. Finally, a new methodology for the leading edge of the waterjet is described and can be incorporated into the erosion simulation by making use of the ``top-hat`` profile generated in the CFD model. This would reduce reliance on model constants to account for secondary cutting, or when particles do not contribute to cutting but are simply entrained in the fluid flow.</p> <p>Both models demonstrated good correlation with experiments or literature. The use of these models will increase understanding of the complex abrasive waterjet process and reduce the need for costly experiments moving forward.</p> / Master of Applied Science (MASc)

Under år 2008 uppskattades den totala produktionen av kugghjul inom bilindustrin till 2000 – 2500 miljoner detaljer, varav 1000 - 1400 miljoner av dessa är av hög kvalité [1]. För precisionskugghjul med modul under 1 mm kan tidsbegränsning och kostnader kopplade till design av skärverktyget elimineras genom att tillämpa en flexibel tillverkningsmetod som tillexempel abrasiv vattenskärning (AWJM). Denna studie undersöker designen av ett hybridtillverkningssystem konfigurerat kring AWJM samt föreslår finbearbetningsprocess via konventionella bearbetningsmetoder. Den tekniska möjligheten att producera kuggring av hög precision testas med en 5-axlig vattenjetmaskin och utvärderas enligt kvalitets nivåer för DIN-standard. För detta ändamål studerades ett kugghjul med modul 0,55 mm, 199 tänder, 110 mm i ytterdiameter och 72 mm i innerdiameter samt en tjocklek på 6 mm gjord av Armox T500, höghållfast stål. Resultaten visar på hög potential att uppnå ISO standardkvalité för kugghjul. Vissa kvalitetsegenskaper, definierade i DIN- och ISO-standarder, till exempel ytfinhet med låga värden; Ra 0,8 μm, uppnås vid användning av AWJM. Andra kvalitetskännetecken som profilavvikelse är relaterade till parametrar som skäreffekt, matningshastighet, mängd abrasivmedel, etc. Framtagna värden sträcker sig från Q10 och Q11 enligt DIN3967 vilket möjliggör slutoperationer som till exempel slipning. Geometrisk avvikelse, på ovansidan, gav en maximalt värde på 7 μm med en standardavvikelse på 4 μm. Jetstrålens eftersläpning observerades och kan kompenseras för medan resultatet av rundade hörn existerar i alla skärning med AWJ. Radiell förskjutning, tandtjocklek och index avvikelser visar värden som kan förbättras tillsammans med processoptimering, maskinkalibrering och eliminering av inneboende positionsavvikelser i maskinen. Varje enskild geometri kräver specifika processparametrar och CAM-programmens algoritmer behöver vidare optimeras för arbeten med tämligen små geometrier. / Production of gears for the automotive industry during 2008 is estimated to have been between 2000 – 2500 million pieces, from which 1000 to 1400 million pieces were high quality gears [1]. For precision gears with module below 1 mm, the time limitations and costs associated with the design of the cutting tool can be eliminated by using a flexible manufacturing technology such as Abrasive WaterJet Machining (AWJM). This project investigates the design of a hybrid manufacturing system configured by use of AWJM and proposed finishing processes using conventional machining methods. The technical feasibility is analysed to produce high precision ring gears using a 5-axes AWJM system to achieve DIN standards quality levels. For this purpose, a gear with a module of 0.55 mm, 199 teeth and 110 mm in the outer diameter and 130 teeth and 72 mm in the inner diameter with a thickness of 6 mm is studied; the selected material is Armox T500, a high strength steel. The results indicate high potential of producing ISO quality standard gears. Certain quality characteristics defined in DIN and ISO standards, for instance surface roughness – values as low as Ra 0.8 μm, are possible to achieve accurately by using AWJM. Others quality features as profile deviation, are related to parameters as cutting power, feed rate, abrasive feed rate, etc. The displayed values ranged Q10 and Q11 according to DIN3967 which allows for use of further finishing operations such as grinding. The top geometry deviations of a 0.3 mm cut, display a maximum value of 7 μm with an average value of 4 μm. Observed jet lag effects can be improved. Rounded corner effect exists in all AWJ cuts. Runout, tooth thickness and index deviations show values that can be improved together with process optimization, machine calibration and elimination of machine inherent positioning deviations. Each particular geometry needs specific process parameters and CAM software algorithms need further optimization for working with rather small design geometries.