The Influence of Operating Pressure Oscillations on the Machined Surface Topography in Abrasive Water Jet Machining

TL;DR

This study shows how pressure oscillations in abrasive water jet machining affect the surface quality of aluminum, leading to visible irregularities like waviness.

Contribution

The study demonstrates a direct link between hydraulic pressure oscillations and surface striations in abrasive water jet machining.

Findings

Striations on the machined surface occur at intervals matching dominant hydraulic pressure harmonics.

Pressure oscillations are transferred to the operating pressure, influencing surface topography.

FFT analysis confirmed the relationship between pressure frequency and surface irregularities.

Abstract

The aim of this study was to determine the connection between oscillations in operating pressure values and the appearance of various irregularities on machined surfaces. Such oscillations are a consequence of the high water pressure generated during abrasive water jet machining. Oscillations in the operating pressure values are periodic, namely due to the cyclic operation of the intensifier and the physical characteristics of water. One of the most common means of reducing this phenomenon is installing an attenuator in the hydraulic system or a phased intensifier system. The main hypothesis of this study was that the topography of a machined surface is directly influenced by the inability of the pressure accumulator to fully absorb water pressure oscillations. In this study, we monitored changes in hydraulic oil pressure values at the intensifier entrance and their connection with irregularities on the machined surface—such as waviness—when cutting aluminum AlMg3 of different thicknesses. Experimental research was conducted in order to establish this connection. Aluminum AlMg3 of different thicknesses—from 6 mm to 12 mm—was cut with different traverse speeds while hydraulic oil pressure values were monitored. The pressure signals thus obtained were analyzed by applying the fast Fourier transform (FFT) algorithm. We identified a single-sided pressure signal amplitude spectrum. The frequency axis can be transformed by multiplying inverse frequency data with traverse speed; in this way, a single-sided amplitude spectrum can be obtained, examined against the period in which striations are expected to appear (in millimeters). In the lower zone of the analyzed samples, striations are observed at intervals determined by the dominant hydraulic oil pressure harmonics, which are transferred to the operating pressure. In other words, we demonstrate how the machined surface topography is directly induced by water jet pressure frequency characteristics.

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