Papers by Author: Jun Wang

Abstract: The interaction between abrasive waterjet and target is studied by computational fluid dynamics (CFD) and finite element method (FEM). The flow field inside and outside abrasive waterjet (AWJ) nozzle is obtained by CFD software. Then the pressure distribution of the fluid on the target is plotted, which is in well agreement with the force distribution of the AWJ impacting on the target and leads to the material deformation. The interaction between the AWJ and target and the fluid-solid coupling is happened. The cloud figure of the target’s deformation and stress are obtained by FEM software. The AWJ parameters such as the flow velocity, off-set and abrasive volume factor have a great effect on the material deformation and the stress distribution. The study results provide a new method to study abrasive water jet machine mechanism and help to optimize process parameters.

Abstract: In precision milling, the quality of surface finish is an important requirement for workpiece machined. Thus, optimization of cutting parameters is important for controlling the surface quality. In this study, the Taguchi method is used to find the effects of milling parameters on surface roughness in precision milling of 3J33 maraging steel. A model, which is based on the milling parameters and tool geometry, is also proposed in order to predict the surface topography. The experimental results show that milling speed has significant effect on the surface roughness among the milling parameters. Besides, tool geometry and material deformation play important roles in the surface topography.

Abstract: The single-asperity friction of polished single crystal silicon using a cone with a spherical apex tip was quantitatively studied concerning the influence of normal load and scratching cycles. Specific friction equations were presented and the interfacial friction equations were determined by fitting the experiment data obtained in the scratching tests. The influence of different scratch conditions to both the interfacial fiction and the plowing friction was analyzed. This paper aims to understand the mechanisms of friction and material removal of single crystal silicon in micro and nanocutting or polishing.

Abstract: To relax the surface residual stress of fused silica lens or windows irradiated by CO₂ laser, it was proposed to treat it at high temperature above glass strain temperature in the traditional annealing process. However it is a time and energy consuming process, and a distortion will be introduced during the heat treatment. To deal with these problems, annealing temperatures lower than glass strain temperature were applied to the annealing process and a new scheme was designed in this paper. An numerical model was built to simulate the laser induced residual stress and optimize the stress variation in the annealing process. The surface stress of fused silica can be relaxed and deformation induced by heat treating can be ignored.

Abstract: An experimental study is reported to characterise the femtosecond (FS) laser grooving process for Germanium (Ge) substrates. The effects of process parameters, including laser fluence, pulse repetition rate and scan speed, on the groove characteristics, material removal rate (MRR) and heat affected zone (HAZ) size are discussed. It is shown that with properly selected process parameters, high quality micro-grooves can be obtained on Ge wafers. Recommendations are finally made on the selection of the most appropriate process parameters for FS micro-grooving of Ge substrates.

Abstract: Abrasive waterjet machining involves the impact of micro-particles at high or ultrahigh velocities. The material removal mechanism for ductile materials has been popularly accepted for over a half century as cutting wear and deformation wear caused by the component of impact force parallel and perpendicular to the target surface respectively. However, this definition of erosion mechanisms does not give an insight into the erosion process, but describes a surface phenomenon of the event. A computational study has been undertaken to reveal the underlying mechanisms of the material removal process. Based on the findings, the impact erosion mechanisms are re-defined as material destruction through (a) failures induced by inertia, (b) failure induced by elongation, and (c) failure induced by adiabatic shear bending. This new definition appears to better represent the physical process of material deformation and removal by loose micro-particle impacts at high and ultrahigh velocities.

Abstract: Laser-assisted waterjet micro-machining can significantly reduce the thermal damages to the workpiece as compared to the traditional laser machining process, and hence can overcome the problems associated with laser machining, such as the formation of heat-affected zone, which is a serious issue for thermal sensitive and functional materials. An experimental study on micro-grooving of monocrystalline silicon wafers is reported in this study to explore the effects of process parameters on the groove depth and width as well as the heat-affected zone (HAZ) width. Predictive models based on dimensionl analysis are then developed for estiamting the groove characteristics.

Abstract: Single crystal silicon carbide (SiC) is a new semiconductor material that has a great potential to be widely used. However, SiC is a kind of difficult-to-machine material due to its extreme hardness and brittleness. The present study investigated the machinability of single crystal SiC using dry laser and three different water-laser co-machining processes. The results indicate that using the hybrid laser-waterjet micro-machining to micro-groove single crystal SiC can derive the clean and straight edges and thermal damage-free grooves.

Abstract: The milling of AISI 321 stainless steel which has wide engineering applications particularly in automobile, aerospace and medicine is of great importance especially in the conditions where high surface quality is required. In this paper, L16 orthogonal array design of experiments was adopted to evaluate the machinability of AISI 321 stainless steel with coated cemented carbide tools under finish dry milling conditions, and the influence of cutting speed ( V ), feed rate ( f ) and depth of cut ( a_p ) on cutting force, surface roughness and tool wear was analysed. The experimental results revealed that the cutting force decreased with an increase in the cutting speed and increased with an increase in the feed rate or the depth of cut. The tool wear was affected significantly by the cutting speed and the depth of cut, while the effect of the feed rate on the tool wear was insignificant. With the cutting speed increased up to 160 m/min, a decreasing tendency in the surface roughness was observed, but when the cutting speed was further increased, the surface roughness increased. The effect of the feed rate and the depth of cut on the surface roughness was slight.

Abstract: Gear grinding is expensive and difficult to research due to its complex kinematics and meshing theory. In the paper, a simplified method based on the meshing model of spiral bevel gear system is presented. With the relative speed and normal curvature of tooth surfaces and grinding wheels on meshing point deduced from differential geometry theory and grinding parameters, the spiral bevel gear grinding can be simplified to fundamental grinding process like surface, cylindrical and internal grinding, which may be utilized to perform experimental investigation on mechanism of gear grinding.