Research Papers

AWJ Milling of Gamma Titanium Aluminide

[+] Author and Article Information
Mohamed Hashish

 Flow International Corporation, Kent, WA 98032

J. Manuf. Sci. Eng 132(4), 041005 (Jul 22, 2010) (9 pages) doi:10.1115/1.4001663 History: Received September 13, 2009; Revised April 01, 2010; Published July 22, 2010; Online July 22, 2010

A study was undertaken to determine the feasibility of the AWJ process for controlled depth milling of gamma Titanium Aluminide tiles. It was demonstrated that milling can be accomplished to 0.025-mm accuracy. To overcome undercutting near rib roots, the jet was clock-angled at about 15 deg to the vertical every set of passes. This allowed the milling to thin skins of about 0.5-mm. It was observed that as the material is milled, stresses were relieved, and either deformation or cracking may result. Accordingly, parts need to be annealed before milling. The milling to thin skins was successfully demonstrated on 150×300mm2 parts without adverse effects. Also, the process of milling of the dual rib height was developed using the dual mask approach. Abrasive particle embedding on the milled surfaces was observed to be about 0.15% of the area, but cleaning with plain waterjets showed that all embedded particles can be removed. A detailed economic analysis confirmed that the AWJ milling process is relatively inexpensive and highly productive. The complete cost of milling including mask cutting, overhead, capital, and running cost is less than 300USD/ft2.

Copyright © 2010 by American Society of Mechanical Engineers
Topics: Milling
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Figure 1

Radial and rotary milling

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Figure 2

Milling setup showing nozzle, turntable, mask, shield, and catcher

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Figure 3

Effect of overlap on milling of Ti/Al

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Figure 4

Effect of tangential velocity

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Figure 5

Effect of pressure on milling of Ti/Al

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Figure 6

Effect of abrasive flow rate on milling of Ti/Al

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Figure 7

Effect of standoff distance on milling of Ti/Al

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Figure 8

Effect of abrasive size on milling depth

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Figure 9

Effect of abrasive mesh size on surface finish

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Figure 10

Effect of number of cycles on depth of cut progression

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Figure 11

Nozzle tile workpiece geometry

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Figure 12

Small opening and large-opening masks used for dual height rips milling

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Figure 13

Milled parts with two different strategies

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Figure 14

Dual masks for full size part

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Figure 15

Full size part and a mask

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Figure 16

Embedded garnet particle

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Figure 17

Embedding free surface after waterjet wash

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Figure 18

Part cracking and damage due to residual stress relief

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Figure 19

Milled part without cracking




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