Original Article

Influence of the nozzle inclination during an assisted machining based on an orthogonal cutting configuration of a titanium alloy: A CFD modeling

¹ Laboratoire de Génie Mécanique, Ecole Nationale d’Ingénieurs de Monastir, Université de Monastir, Tunisie
² Institut Préparatoire aux Etudes d’Ingénieur de Monastir, Université de Monastir, Tunisie
³ Electrical & Computer Engineering Department, College of Engineering, Dhofar University, Salalah, Oman

^* e-mail: ikrambenbelgacem@gmail.com

Received: 20 August 2023
Accepted: 23 May 2024

Abstract

This study delves into the characteristics of a water jet impacting a stationary target, employing Computational Fluid Dynamics (CFD) simulations conducted with ABAQUS/CFD 6.14. Inspired by an orthogonal cutting configuration of a Ti6AL4V alloy during high-pressure water jet-assisted machining, the paper investigates the effect of nozzle inclination angles ranging from 6° to 81°. Utilizing the Finite Volume (FV) method, the jet impacts the target with an initial velocity of 223 m/s through a 0.7 mm diameter nozzle, positioned 6 mm away from the target center. Additionally, simulations were conducted for a 23° inclined jet to analyze the influence of nozzle diameter ’D’ across a range of 5 values from 0.3 mm to 1.1 mm, with a step of 0.2 mm. Turbulence phenomena are addressed using the K-ε model. Results indicate that a 23° inclination yields significant pressure values, enhancing chip fragmentation. Furthermore, recirculation phenomena intensify with inclination, highlighting the importance of nozzle diameter reduction for achieving a more laminar jet and precise injection, albeit with reduced cutting edge pressure. Moreover, the study introduces a novel approach to construct a new equivalent jet with modified boundary conditions to tackle fluid-structure coupling limitations, mitigating speed drops and turbulence phenomena. While thermal effects are excluded in this study, acknowledging the importance of sufficient cooling in machining operations, the findings provide valuable insights into the mechanical dynamics of machining processes. Additionally, the paper serves as a guideline for researchers, particularly those engaged in computational fluid dynamics within machining, shedding light on the underexplored area of numerical modeling of High-Pressure Lubrication (HPL) using software like Abaqus/CFD