Papers by Author: Hong Tao Zhu

Abstract: Micro abrasive air jet (MAAJ) cutting is a promising technology for the fabrication of three-dimensional microstructures in hard and brittle materials. In this paper, a study on the cross-sectional shape of the kerf cut with MAAJ is presented. It shows that the machining depth and slope of the sidewall increase with an increase in air pressure, abrasive flow rate and jet incidence angle, while decrease with an increase in nozzle traverse speed. Using a dimensional analysis technique, predictive model for cross-sectional profile is developed. The research results may be meaningful to the highly precision three-dimensional micro-structural cutting.

Abstract: In this paper, the influence of the incidence angle and abrasive mesh on the polishing quality is analyzed during AWJ polishing process. Through the study on the jet flow structure, it is obtained the standoff of AWJ polishing is chosen within the jet basic section. According to the experiments for AWJ Polishing quartz, it is better to remove material by ductile removal mechanism choosing small incidence angle, low pressure and small abrasive size. The ductile removal mechanism of the polished material is a necessary condition for the ideal polishing results

Abstract: Micro abrasive air jet (MAAJ) cutting technology is being increasingly used in the precision machining of hard and brittle materials, due to its distinct advantages of negligible heat effect zone and small cutting force. In this paper, an experimental study on the kerf characteristics, especially for the effect of cutting parameters on the top edge definition, is presented. It shows that the top kerf edge is straight but not sharp. The top edge definition of the kerf improves with a decrease in the air pressure, while the effect of abrasive flow rate and nozzle traverse speed are hardly discernible. The optimum jet incidence angle for highest top edge definition of the kerf is 60°. The results of this paper may be useful for the cutting parameters optimization in the precision three-dimensional micro-structural machining.

Abstract: Micro abrasive air jet machining technology is being increasingly used in the fields of micro cutting. Since the aspect ratio is a major interest characteristics of kerf in micro cutting, an experimental investigation is carried out to study the effect of cutting process parameters on the aspect ratio in this study. It is found that the aspect ratio increases with an increase in air pressure, abrasive flow rate and jet incidence angle, while decreases with an increase in nozzle traverse speed. Furthermore a predictive model for aspect ratio is developed using the dimensional analysis technique. It is shown that the model predictions are in good agreement with the experimental results. The research results may be meaningful to efficiently control the aspect ratio.

Abstract: In this paper, a study on erosion mechanism of Ultrasonic Vibration Abrasive Waterjet is presented. Theoretical analysis of the total effective erosion kinetic energy of UVAWJ is performed. By using a UVAWJ machining system with an Ultrasonic Vibration Power Workbench, the comparative experiment is conducted. The erosion surfaces of the single crystal silicon substrate were measured by Optical Profiler and observed with Scanning Electron Microscope. The material removal mechanisms are discussed. It is concluded that the erosion by UVAWJ, with the aid of high-frequency ultrasonic vibration, can obtains a high material removal, less cracks and good finish surface.

Abstract: This paper conducts a study on a precision micro abrasive waterjet (PMAWJ) machining system. A new kind of precision micro abrasive water jet system is designed and tapped. The flux and the flow velocity of the PMAWJ system are tested by experiments. Using the micromachining system, a group of polishing experiments is conducted for two kinds of hard-brittle materials such as silicate glass and silicon nitride. The results show the feasibility and the advantage of the PMAWJ machining system for polishing hard-brittle materials.

Abstract: Simulation of the gas-liquid-solid three-phase flow field of outside the abrasive water jet(AWJ) nozzle is studied by the computed fluid dynamic software- FLUENT, and the velocity field of the three-phase flow is obtained, the velocity value of the flow between the nozzle and work-pieces is also obtained. Serial experiments have been done to verify the simulation method. In the experiments, the impact force signal of the AWJ outside the nozzle is collected by the piezoelectricity ergometer, then it is filtered by the vibration signal and dynamic signal software. The testing values are transformed to the velocity values, which will be compared with the simulation values. The comparison result indicates that the value of the simulation is changing similarly with the experiment value, and both value is almost the same, which proves that the simulation method is successful, the simulation model and the boundary conditions are right.

Abstract: The abrasive waterjet machining is a powerful tool in processing various materials, especially, for brittle materials, such as ceramic, glass and so on. However, the material removal of a brittle material when impacted by abrasive waterjet is not understood in detail. In this paper, the material removal model in fracture erosion of brittle materials by abrasive waterjet has been developed.

Abstract: In this paper, the impact pressure of abrasives acting on the polished materials was deduced by Field Theory and the model of surface roughness for polishing super hard materials with Abrasive Water Jet (AWJ) was established. The model indicates that the surface roughness increases linearly with an increase in the maximum depth of abrasives indenting into materials and that the relationship between the surface roughness and polishing parameters including water pressure, abrasive pressure, the impact angle, the hardness of the polished material, the elastic distortion of abrasive, abrasive size, abrasive density, nozzle diameter and standoff.

Abstract: The erosion process of abrasive waterjet (AWJ) on target material is very complicated and a complete clear understanding about material removal mechanisms in AWJ machining has not been obtained. In this paper, an experiment study on AWJ machining mechanisms of brittle materials is introduced so as to understand the actions of water jet and abrasive particle in material removal process and some experiment evidences of the change of material removal mechanisms have been obtained.