WATER JET CONFERENCE - Waterjet Technology Association

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DEVELOPMENT OF VARIABLE DELIVERY TRIPLE RECIPROCATING PLUNGER PUMP FOR <strong>WATER</strong> <strong>JET</strong> CUTTING Masao Nakaya, Nobuo Nishida, Takashi Kitagawa Sugino Machine Limited, Japan ABSTRACT With recent development of practicability of the water jet in various industries, advantages are being recognized in its special processing method. Particularly, it is most used for cutting of non-metallic materials and detergent operation, using its water hammer power and chemical solubility. Diversification in the range of applicability is requiring various specifications of high presure pump as a source of water jet. In cutting and detergency, it is necessary to control water jet pressure according to the object material in view of economy and efficiency. High operational efficiency is demanded of a pump by obtaining a delivery volume corresponding to the change of water jet flow. For these objectives, we have elaborated the development of a variable delivery triple reciprocating plunger pump, and, based on its design, succeeded in the manufacture of a high pressure pump. This report provides explanation of its structure and analysis of the results of tests. As a consequence, its high efficiency and small pulsation of water jet has assured the possibility of application in a number of industrial areas. NOMENCLATURE Symbol Description A1 Sectional area of piston (cm 2 ) A2 Sectional area of plunger (cm 2 ) N Number of revolutions of crank shaft (rpm) P1 Pressure of hydraulic cushion cylinder (MPa) P2 Pressure of high pressure cylinder (MPa) Q Maximum delivery capacity of pump (l/min) Q1 Volume of circulating oil inflow to the hydraulic cushion cylinder (l/min) Q2 Volume of injection from the nozzle (l/min) q1 Volume of a single inflow of oil to the hydraulic cushion cylinder (cm 3 ) S Piston stroke (cm) S2 Plunger stroke in the Q2 delivery (cm) W Required power for totaldelivery (kW) W1 Conductive power to crank shaft from piston (kW) W2 Retentive power of Q2 (kW) η Nozzle efficiency INTRODUCTION An injection of high pressure water from a minute nozzle produces high density of energy increasingly utilized for new processing techniques in many industries. A waterjet of relatively low pressure and large flow is widely used in detergency. An efficient application represents the important station of an automobile assembly line to remove residual powder on mechanically processed engines and transmissions. Also in a chemical plant, a water jet is used for detergency of a polymer tank to assure safety of workers 136
from poisonous gas. On the other hand, a water jet of relatively high pressure and small flow volume is seeking its application in the cutting operation, the objectives of which vary from paper diaper to compound materials for an aircraft to reflect the continuing expansion of applicability. With development of new materials, an effort to automate the cutting operation requires a wide range of applicable cutting pressure. And naturally, careful consideration should be given to maintain the life of machinery and a reasonable running cost. Generally, a water jet for the cutting operation needs a delivery pressure of more than 196 MPa and its maximum pressure is about 440 MPa. The high pressure pump used for this purpose is divided into two categories: a hydraulic booster pump and a crank structured closed coupled multiple plunger pump. These high-pressure pumps require: i) Easiness of pressure control ii) High efficiency iii) Little pressure change It goes without saying that the basic factors include a long life and easy maintenance. Practicability of the water jet for the cutting operation needs to be analyzed further. In the actual cutting operation, it is necessary to control the volume of water jet from the nozzle. A stop of the injection from the nozzle necessitates a total relief of the high-pressure water or prevention of occurrence of a high pressure. A decrease of nozzles in the cutting process causes a drop of delivery volume and consequently requires regulation of the high pressure water volume . For these purposes, many years have been spent for research and development in pursuit of an efficient variable delivery high pressure pump that permits easy control of pressure and wide flexibility of delivery volume. For the control of pressure, the closed coupled plunger pump has a relief valve on the high-pressure water side, and the hydraulic booster pump has a function of regulating the primary hydraulic pressure. For the flexibility of delivery volume, the eccentricity of the crank shaft or the number of revolutions is changed to increase efficiency of the closed coupled plunger pump, while the hydraulic booster pump is equipped with a variable delivery pump in the oil circuit. In these circumstances, we have developed a brand-new variable delivery triple reciprocating plunger pump (Sugino Aqua Jet Pump Mechanical Drive). This is a new type hybrid pump having a hydraulic cushion cylinder between the crank structure and the high pressure plunger that yields high efficiency and capacity of controlling the injection pressure of more than 196 MPa. Further, the resultant negligible pulsation permits the application in various industries especially for the water jet cutting pump. We will explain its structure and analyze the characteristics, hoping that they would constitute foundations that contribute to expand the range of applicability. 137
Page 1 and 2:
Proceedings of the Second U.S. WATE
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Visualization of the Central Core o
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A Status Report on the Conceptual D
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SESSION 7 - CIVIL & INDUSTRIAL Chai
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Cutting Hard Rock With Abrasive-Ent
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frictional and piping component rel
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R = a1 ⋅ A1 A2 a2 I = 2H o Q o
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attenuation of the output. The tran
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Figure 1. Branch System Modulator F
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Figure 5. Modulation Response for B
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Figure 9. Modulation response for s
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can be used for any form of input.
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with a cylindrical shape to the jet
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m/s. The range of power found from
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Figure 3. Power vs nozzle diameter
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Figure 5. Frequency vs length of th
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NAME: Gerald Zink COMPANY: StoneAge
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modulatornozzle assembly. The ordin
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DISCUSSION OF FLUID MECHANICS The i
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This process serves to protect the
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For test purposes, these concrete b
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REFERENCES CITED 1. Barker, C. R.,
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FIGURE 4. INNER CORE OF PERCUSSIVE
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FIGURE 9. EXAMPLE OF HIGH-PRESSURE
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NAME: John E. Wolgamott COMPANY: St
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THE FOCUSED SHOCK TECHNlQUE FORPROD
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The reflected wave is thus also cyl
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neglected. The introduction of a co
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DISCUSSION NAME: George Savanick CO
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H’ mean shape factor Hj theoretic
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Required streamline curvature at th
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2 x 2 ≅ ( e − 2 p + w)/k2 (2-8)
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eliminating 2 n r 2 from equations
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approximation to the actual flow si
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skin friction coefficient but are c
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where: (H) = A1H 3 + A2H 2 + A3H +
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effect (< 0.5%) on coefficients of
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TABLE 5 Rei x 10 5 β 3 4 5 6 Po Po
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TABLE 6 D(mm) d o(mm) L t(mm) L f(m
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expanding rather than contracting a
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25. Weber, H.E., 1978, Boundary lay
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Figure 5. Wall velocity distributio
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Figure 9. Effect of nozzle design o
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Figure 12. CA+T Design Philosophy.
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Figure 16. Effect of inlet b 1 cond
Page 92 and 93: Figure 20. Relaminarization at nozz
Page 94 and 95: Figure 24. Pressure decay data. 88
Page 96 and 97: VISUALIZATION OF THE CENTRAL CORE O
Page 98 and 99: DISCUSSION Although employing the i
Page 100 and 101: 5. Lambert, J. H., 1760, Photometri
Page 102 and 103: Figure 6. Spectral sensitivity curv
Page 104 and 105: NAME: W.C. Cooley COMPANY: Terraspa
Page 106 and 107: INTRODUCTION Pulsed liquid jets sho
Page 108 and 109: y=X ∨ P A dy = p p A p 2 (L c y=0
Page 110 and 111: Using equation (15), the value of X
Page 112 and 113: Thus about the first 10% of the dri
Page 114 and 115: Many design cases, including those
Page 116 and 117: surface spall occurred, resulting i
Page 118 and 119: Figure 3. Chamber pressure at pisto
Page 120 and 121: Figure 7. Effect of nozzle area rat
Page 122 and 123: Figure 11. Extrusion device schemat
Page 124 and 125: Figure 15. Typical chamber pressure
Page 126 and 127: DISCUSSION NAME: W. C. Cooley COMPA
Page 128 and 129: material which are, in turn, affect
Page 130 and 131: the water jet. This method was not
Page 132 and 133: where h is the depth of penetration
Page 134 and 135: obtained during this phase of the i
Page 136 and 137: observed that the smallest depth of
Page 138 and 139: Figure 2. Idealized Relationships b
Page 140 and 141: Figure 6. Penetration as a Function
Page 144 and 145: THE STRUCTURE AND FUNCTION OF THE P
Page 146 and 147: The injection pressure can be contr
Page 148 and 149: ACKNOWLEDGEMENTS The authors gratef
Page 150 and 151: Figure 4. Theoretical required powe
Page 152 and 153: Figure 9. Variation of efficiency w
Page 154 and 155: THE "SKIPJACK" SEWER CLEANING NOZZL
Page 156 and 157: HYDRO-BLASTING SAFETY C.W. Adaway,
Page 158 and 159: Remember, your Hydro-Blasting work
Page 160 and 161: horizontal, sometimes vertical, and
Page 162 and 163: Figure 2. Safety Gear Figure 3. Tub
Page 164 and 165: DEVELOPMENTS IN CLEANING COKE OVEN
Page 166 and 167: causing chain breakages and the scr
Page 168 and 169: was encountered, then the rotation
Page 170 and 171: (C) Capital Expenditure: Material i
Page 172 and 173: Figure 9. Swivel coupling Figure 10
Page 174 and 175: OPTIMIZING JET CUTTING POWER FOR TU
Page 176 and 177: PRESSURE DROP (psi) ELEMENT Cv @10
Page 178 and 179: power output. Undersized nozzles re
Page 180 and 181: Subscripts n - Nozzle p - Pump t -
Page 182 and 183: Figure 1. Cutting effect as a funct
Page 184 and 185: CONSIDERATIONS IN THE COMPARISON OF
Page 186 and 187: pressure can be lowered to perhaps
Page 188 and 189: Figure 2: Fan jet issuing from a no
Page 190 and 191: DISCUSSION NAME: John Griffiths COM
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where Q = Flow rate - gpm D = Jet O
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Again, not limited to Newtonian flu
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REFERENCES 1. Brown, R.W. and Loper
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Table 2. Jet Cleaning Speeds and ot
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ANSWER: The utilization of the stat
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complexity and short component life
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Figure 4, for ap values ranging fro
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Decontamination Methods for rapidly
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a. “PULSER” b.”ORGAN-PIPE”
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Figure 5 - Removal rate for various
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DISCUSSION NAME: David A. Summers C
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DRILLING BORE HOLES IN COAL MINES U
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pile could not be judged as represe
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DISCUSSION NAME: David Summers COMP
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HYDRAULIC MINING EXPERIMENTS IN AN
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The monitor was fed pressurized wat
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The IH rig was considered to be sup
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REFERENCES 1. Okhrimenki, V. A., A.
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Figure 2. Jet cutting sandstone at
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Figure 5. Schematic plan view of In
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Figure 7. Suction Box. 226
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USE OF HIGH PRESSURE WATER JETS FOR
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flame torch to cut this block, redu
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the order of 360 rpm. Under these c
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Figure 3. Slot cut by jet at 11 o s
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JET-MINER SURFACE AND IN-SEAM TRIAL
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The hydraulic drive of the haulage
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The surface trials had have the obj
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Figure 2. Experimental version. Fig
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Figure. 7 Jet-Miner prototype Figur
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SOME PATTERNS OF TECHNOLOGY TRANSFE
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Development of High Pressure_Techno
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configurations, the design of an op
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and public sectors. After a haitus
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Souder, W.E. and Evans, R.J., "The
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Figure 5. Technological achievement
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Table 3. Perceived disadvantages of
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already been, or is being applied w
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Using the requirements profile and
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ant hose combination, a guiding sys
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HYDRAULIC MINING TESTS Site selecti
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SAFETY All operations were carried
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TABLE V. Categories of Jet Mining D
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Figure 2. Generalized geologic prof
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SECONDARY FRAGMENTATION WITH WATER
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do possess a maximum point (Fig. 8)
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Figure 4. Rossin-Rammler plot. Figu
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Figure 8. Non-dimensional plot for
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HYDRAULIC COAL MINING SYSTEM Typica
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Figure 4. (From ref. 1) DISCUSSION
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INTRODUCTION Developing an unique t
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The coefficients "b " in Eq. (1) ca
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By the end of 1982, a total of more
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Figure 4. Cutting ability of swing-
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Figure 10. An operating performance
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for an abrasive, the abrasive parti
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the particles, while at slower spee
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to break away the remaining segment
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Table 1. Concrete saw technology. T
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NAME: Tom Brunsing COMPANY: Foster-
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FEASIBILITY STUDY OF CUTTING SOME M
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hydraulic power required to cut thr
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pressure was varied from 103 to 310
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2.1 Heading and gutting fresh cod f
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Figure 5. The cuts surface of a blo
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Figure 17. Cuts made across the cla
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JET NOTCHING USED IN THE CONSTRUCTI
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Bottom notch diameter was determine
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σ H = in-situ stress in the horizo
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Figure 3. Final block displacement.
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Figure 8. Comparison of Slurry Pump
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THE FURTHER DEVELOPMENT OF AN UNDER
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use taps or hydrants. To achieve th
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supply line. It was determined that
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The rotating head requires major mo
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Figure 4. System field test set-up
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Figure 10. Bentonite drilled clay s
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MECHANICAL TOOLS Cutting Tool Energ
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Ψ = cos −1 ⎧ ⎪ ⎪ ⎨ ⎪
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mode also contributes to chip flush
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NAME: Simon Johnson COMPANY: Newcas
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ROLLER TOOLS COMBINED WITH HIGH-PRE
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Various designs and applications ar
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Figure 1. Full-face tunneling machi
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Figure 11. roadway profile cutting
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Figure 19. High-pressure water jet
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DESIGN AND OPERATION OF TWO LARGE-S
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The hydraulic system for the thrust
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Results of Trial Tests As part of m
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cutting rates, degree of bit wear,
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Overall approximate Weight: Basic M
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Figure 5. 3 ft. diameter laboratory
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nozzle diameter and cutting speed w
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2. Cutting Speed The influence of c
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energy it effects an increase in me
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Tip angle (degrees) 87 Off-set angl
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Figure 5. Figure 6. Figure 7 Figure
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Figure 17. Figure 18. Figure 19. Fi
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SCHEMES OF COAL MASSIF BREAKAGE BY
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out thoroughly an efficient scheme
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Research analysis has proved that t
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DEPENDENCE OF POWER INDICES OF COMB
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The experiments have shown how the
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K Ay = coefficient correcting for f
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Figure 1. Schemes of combined break
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Figure 5. Dependence of specific en
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Figure 12. Percentage of grade R -6
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Figure 1. Particle size analysis. T
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NAME: Dr. Henkel COMPANY: Bergbau-F
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presented. This study, of course, i
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identifying a general trend for the
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Effect of Abrasive Hardness, Shape
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In some situations, especially in c
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Figure 1. Abrasive waterjet nozzles
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Figure 8. Effect of standoff distan
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Figure 13. Abrasive waterjet cuts i
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CUTTING WITH ABRASIVE WATERJETS M.
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3.3 Abrasive Feed Systems For abras
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Because of the large number of infl
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due to wear. Although actual operat
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from this new technology. Table 2 l
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Table 1. materials cut by abrasive
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Figure 1. Abrasive waterjet nozzles
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a) kerfs in mild steel b) S.S. 15.5
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a) circle cutting in glass b) lamin
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DISCUSSION NAME: Andrew F. Conn COM
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CUTTING HARD ROCK WITH ABRASIVE-ENT
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slurry nozzle. Testing at water pre
Page 448 and 449:
DISCUSSION OF TEST RESULTS Jet Conf
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materials. The flexibility in nozzl
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pressure can be wiped out if diffic
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9. Maurer, W.C., and Heilheckler, J
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Figure 5. Effect of abrasive feed r
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Figure 9. Accumulated depth of mult
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Figure 13. Close-up view of quartzi
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ABRASIVE INJECTION USAGE IN THE UNI
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sudden changes in the feed rate eff
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or the abrasive must be manually to
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clog; there not being sufficient ar
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CODE OF PRACTICE FOR THE USE OF ABR
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Figure 5. Water abrasive cleaning h
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Figure 15. 360 0 abrasive pipe clea
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ECONOMIC CONSIDERATIONS IN WATER JE
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Other criteria to be considered in
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3 MANUAL METHODS OF JET CLEANING &
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contractor with old, unsafe, equipm
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Figure 1. Showing the increased cos
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Figure 8. Automatic tube bundle cle
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ackground to the subsequent coopera
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The molecules of SUPER-WATER posses
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shaken just before use. SUPERWATER
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26. Bednarz, L.P., "Effects of Poly
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