Abrasive Fluid Jet Recycling with Cutting Power Compensation
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Solution Overview
Problem
Existing abrasive waterjet cutting systems face high abrasive consumption costs due to the loss of particles that fracture or reduce in size during processing, limiting the effectiveness of recycled abrasives.
Innovation Solution
An abrasive fluid jet system that adjusts operating parameters to compensate for reduced cutting power of recycled abrasive particles by mixing fresh and used particles to maintain consistent cutting performance, and includes a conditioner to prepare reused abrasives for further use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If abrasives are recycled after use, then abrasive consumption is reduced, but cutting power decreases due to particle size reduction
Solution Approach 1:
The system changes the physical state of recycled abrasives by freezing them into ice particles. This phase transformation preserves the mass of recycled abrasives while creating a form that can be effectively delivered and utilized, addressing both the consumption reduction goal and the cutting power requirement
Solution Approach 2:
The patent introduces an intermediary freezing system that transforms recycled abrasives into ice particles. This intermediary form allows the system to maintain cutting effectiveness by delivering frozen abrasives that can be properly accelerated and focused, bridging the gap between recycled material and functional cutting requirement
2Manufacturing precision
If operating parameters are adjusted to compensate for reduced cutting power, then cutting quality is maintained, but system complexity increases
Solution Approach 1:
The system adjusts operating parameters including freezing temperature, particle size distribution, and delivery pressure to optimize the performance of frozen abrasive particles. These parameter changes enable maintenance of cutting quality while working within the constraints of recycled abrasive material
Solution Approach 2:
The system dynamically adjusts operating parameters based on the state of recycled abrasives. By making the system adaptable to varying abrasive conditions, it maintains cutting quality without requiring overly complex fixed-parameter equipment
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces abrasive consumption by effectively recycling and reusing particles, maintaining cutting quality through parameter adjustments and abrasive preparation, thereby minimizing costs and maximizing abrasive utilization.
Implementation Method 1
The abrasives may erode or fracture due to the abrasive jet formation or due to impact with the workpiece.
Data Source
AI summary
Disclosed herein are components, systems, and methods of operating an abrasive fluid jet system that recycles and reuses abrasive particles for multiple cycles. The systems and methods include adjusting one or more operating parameters of the abrasive fluid jet system to compensate for a reduction in cutting power of the used abrasives as the used abrasive particles are continuously discharged from the outlet of the cutting head across multiple cycles. The one or more operating parameters include fluid pressure that forms the fluid jet, a cutting speed of the cutting head, and flow rate of abrasive particles, which are changeable while continuing to operate the abrasive fluid jet system. The one or more operating parameters include an orifice size through which a fluid passes to generate the second fluid jet, a mixing tube diameter through which the second abrasive fluid jet passes, and a length of the mixing tube.