Abrasive Jet Machining - Process variables and current applications

brusive Jet Machining (AJM) or Micro Blast Machining is a non-traditional machining process, wherein material removal is effected by the erosive action of a high velocity jet of a gas, carrying fine-grained abrasive particles, impacting the work surface. The AJM process differs from conventional sand blasting in that the abrasive is much finer and the process parameters and cutting action are carefully controlled. The process is particularly suitable to cut intricate shapes in hard and brittle materials which are sensitive to heat and have a tendency to chip easily. In other words, AJM can handle virtually any hard or brittle material. Already the process has found its ways Into dozens of applications; sometimes replacing conventional alternatives often doing jobs that could not be done in any other way. This paper reviews the current status of this non-conventional machining process and discusses the unique advantages and possible applications.

A model supersonic buried-nozzle jet: instability and acoustic wave scattering and the far-field sound

We consider sound source mechanisms involving the acoustic and instability modes of dual-stream isothermal supersonic jets with the inner nozzle buried within an outer shroud-like nozzle. A particular focus is scattering into radiating sound waves at the shroud lip. For such jets, several families of acoustically coupled instability waves exist, beyond the regular vortical Kelvin-Helmholtz mode, with different shapes and propagation characteristics, which can therefore affect the character of the radiated sound. In our model, the coaxial shear layers are vortex sheets while the incident acoustic disturbances are the propagating shroud modes. The Wiener-Hopf method is used to compute their scattering at the sharp shroud edge to obtain the far-field radiation. The resulting far-field directivity quantifies the acoustic efficiency of different mechanisms, which is particularly important in the upstream direction, where the results show that the scattered sound is more intense than that radiated directly by the shear-layer modes.

Studies on abrasive jet machining through statistical design of experiments

The main objective of statistical analysis of experi- mental investigations is to make predictions on the basis of mathematical equations so as the number of experiments. Abrasive jet machining (AJM) is an unconventional and novel machining process wherein microabrasive particles are propelled at high veloc- ities on to a workpiece. The resulting erosion can be used for cutting, etching, cleaning, deburring, drilling and polishing. In the study completed by the authors, statistical design of experiments was successfully employed to predict the rate of material removal by AJM. This paper discusses the details of such an approach and the findings.

CMC simulations of lifted turbulent jet flame in a vitiated coflow

Lifted turbulent jet diffusion flame is simulated using Conditional Moment Closure (CMC). Specifically, the burner configuration of Cabra et al. [R. Cabra, T. Myhrvold, J.Y. Chen. R.W. Dibble, A.N. Karpetis, R.S. Barlow, Proc. Combust. Inst. 29 (2002) 1881-1887] is chosen to investigate H-2/N-2 jet flame supported by a vitiated coflow of products of lean H-2/air combustion. A 2D, axisymmetric flow-model fully coupled with the scalar fields, is employed. A detailed chemical kinetic scheme is included, and first order CIVIC is applied. Simulations are carried out for different jet velocities and coflow temperatures (T-c) The predicted liftoff generally agrees with experimental data, as well as joint-PDF results. Profiles of mean scalar fluxes in the mixture fraction space, for T-c = 1025 and 1080 K reveal that (1) Inside the flame zone, the chemical term balances the molecular diffusion term, and hence the Structure is of a diffusion flamelet for both cases. (2) In the pre-flame zone, the structure depends on the coflow temperature: for the 1025 K case, the chemical term being small, the advective term balances the axial turbulent diffusion term. However, for the 1080 K case. the chemical term is large and balances the advective term, the axial turbulent diffusion term being small. It is concluded that, lift-off is controlled (a) by turbulent premixed flame propagation for low coflow temperature while (b) by autoignition for high coflow temperature. (C) 2009 The Combustion Institute. Published by Elsevier Inc. All rights reserved.

Buoyant Jet Discharges into Finite Ambient Waters

The paper presents the results of an experimental study regarding the effect of the lateral dimension of the receiving water on the spreading, mixing, and temperature decay of a horizontal buoyant surface jet. The widths of the ambient water in the experiments have been 240, 120, 90 and 60 times the diameter of the jet nozzle. Based on the experimental data, correlations are carried out and empirical equations for prediction of jet width, thickness in vertical direction and longitudinal temperature decay are obtained. The available data of earlier investigators are included to obtain generalized equations for the spreading and temperature decay. Similarity of temperature profiles in the lateral and vertical directions is observed. The longitudinal temperature decay is found to vary inversely with distance in the flow direction and ¼th power of the densimetric Froude number.

Impact of African orography and the Indian summer monsoon on the low-level Somali jet

The low-level jet (LLJ) over the Indian region, which is most prominent during the monsoon (June-September) season, has been studied with a general circulation model (GCM). The role of African orography in modulating this jet is the focus of this article. The presence o African orography intensifies the cross-equatorial flow. Contrary to previous modelling Studies we find that cross-equatorial flow occurs even in the absence of African orography, though this flow is muc weaker even when the Indian monsoon rainfall is high. However, the location of the meridional jet near the equator in the Somali region is linked to the Indian monsoon rainfall rather than to the land-sea contrast over Somalia. Also, the presence of African orography, and not the strength of the Indian monsoon, controls the vertical extent of the equatorial meridional wind. In an aqua-planet simulation, the cross-equatorial flow occurs about 30 to the west of the rainfall maximum. Thus, the longitudinal location of the equatorial Somali jet depends upon the occurrence of monsoon heating, but the vertical structure of the jet is on account of the western boundary current in the atmosphere due to the East African highlands under the influence of monsoonal heat source.

Kinetics of Extraction of Iron(II1) by Bis(2-ethylhexyl Phosphate in a Laminar Liquid-Liquid Jet Reactor

The kinetics of iron(II1) extraction by bis(Zethylhexy1) phosphate (HDEHP, HA) in kerosene from sulfuric acid solutions has been studied in a liquid-liquid laminar jet reactor. The contact time of the interface in this reacting device is of the same order of magnitude as the surface renewal time in dispersion mixing and much less than that obtained in the relatively quiescent condition of the Lewis cell. Yet the analysis of the data in this study suggested a rate-controlling step involving surface saturation quite in conformity with that obtained in the Lewis cell and not with that in dispersion mixing as reported in the literature. Further, the mechanism suggested a weaker dependence of the rate on hydrogen ion concentration which was reported by other workers.

Drag reduction by counterflow supersonic jet for a blunt cone in high enthalpy flows

Counterflow supersonic jet is used as a drag reduction device during the experiments in free piston driven shock tunnel, HST3. Accelerometer based force balance is employed to measure the drag force experienced by the 60-degree apex angle blunt cone model without and with the supersonic jet opposing the hypersonic flow. It is observed that the drag force decreases with increase in injection pressure ratio until the critical injection pressure is reached. Maximum reduction in drag force of 44 percent is recorded at the critical injection pressure ratio 22.36. Further increase in injection pressure ratio has reduced the percentage drag reduction. Change in nature of the flowfield around the model has also been observed across the critical injection pressure ratio.

Experimental and numerical investigation of jet injection in a wall bounded supersonic flow

Numerical and experimental studies of a supersonic jet (Helium) inclined at 45 degrees to a oncoming Mach 2 flow have been carried out. The numerical study has been used to arrive at a geometry that could reduce an oncoming Mach 5.75 flow to Mach 2 flow and in determining the jet parameters. Experiments are carried out in the IISc. hypersonic shock tunnel HST2 at similar conditions obtained from numerical studies. Flow visualization studies carried out using Schlieren technique clearly show the presence of the bow shock in front of the jet exposed to supersonic cross flow. The jet Mach number is experimentally found to be approximate to 3. Visual observations show that the jet has penetrated up to 60% of the total height of the chamber.

Turbulence measurements in an equilibrium axisymmetric wall jet

This paper reports measurements of turbulent quantities in an axisymmetric wall jet subjected to an adverse pressure gradient in a conical diffuser, in such a way that a suitably defined pressure-gradient parameter is everywhere small. Self-similarity is observed in the mean velocity profile, as well as the profiles of many turbulent quantities at sufficiently large distances from the injection slot. Autocorrelation measurements indicate that, in the region of turbulent production, the time scale of ν fluctuations is very much smaller than the time scale of u fluctuations. Based on the data on these time scales, a possible model is proposed for the Reynolds stress. One-dimensional energy spectra are obtained for the u, v and w components at several points in the wall jet. It is found that self-similarity is exhibited by the one-dimensional wavenumber spectrum of $\overline{q^2}(=\overline{u^2}+\overline{v^2}+\overline{w^2})$, if the half-width of the wall jet and the local mean velocity are used for forming the non-dimensional wavenumber. Both the autocorrelation curves and the spectra indicate the existence of periodicity in the flow. The rate of dissipation of turbulent energy is estimated from the $\overline{q^2}$ spectra, using a slightly modified version of a previously suggested method.

Jet Engine Health Signal Denoising Using Optimally Weighted Recursive Median Filters

The removal of noise and outliers from health signals is an important problem in jet engine health monitoring. Typically, health signals are time series of damage indicators, which can be sensor measurements or features derived from such measurements. Sharp or sudden changes in health signals can represent abrupt faults and long term deterioration in the system is typical of gradual faults. Simple linear filters tend to smooth out the sharp trend shifts in jet engine signals and are also not good for outlier removal. We propose new optimally designed nonlinear weighted recursive median filters for noise removal from typical health signals of jet engines. Signals for abrupt and gradual faults and with transient data are considered. Numerical results are obtained for a jet engine and show that preprocessing of health signals using the proposed filter significantly removes Gaussian noise and outliers and could therefore greatly improve the accuracy of diagnostic systems. [DOI: 10.1115/1.3200907].

Prediction of flame liftoff height of diffusion/partially premixed jet flames and modeling of mild combustion burners

In this article, a new flame extinction model based on the k/epsilon turbulence time scale concept is proposed to predict the flame liftoff heights over a wide range of coflow temperature and O-2 mass fraction of the coflow. The flame is assumed to be quenched, when the fluid time scale is less than the chemical time scale ( Da < 1). The chemical time scale is derived as a function of temperature, oxidizer mass fraction, fuel dilution, velocity of the jet and fuel type. The present extinction model has been tested for a variety of conditions: ( a) ambient coflow conditions ( 1 atm and 300 K) for propane, methane and hydrogen jet flames, ( b) highly preheated coflow, and ( c) high temperature and low oxidizer concentration coflow. Predicted flame liftoff heights of jet diffusion and partially premixed flames are in excellent agreement with the experimental data for all the simulated conditions and fuels. It is observed that flame stabilization occurs at a point near the stoichiometric mixture fraction surface, where the local flow velocity is equal to the local flame propagation speed. The present method is used to determine the chemical time scale for the conditions existing in the mild/ flameless combustion burners investigated by the authors earlier. This model has successfully predicted the initial premixing of the fuel with combustion products before the combustion reaction initiates. It has been inferred from these numerical simulations that fuel injection is followed by intense premixing with hot combustion products in the primary zone and combustion reaction follows further downstream. Reaction rate contours suggest that reaction takes place over a large volume and the magnitude of the combustion reaction is lower compared to the conventional combustion mode. The appearance of attached flames in the mild combustion burners at low thermal inputs is also predicted, which is due to lower average jet velocity and larger residence times in the near injection zone.