Desarrollo de un cabezal de corte por chorro de agua para aplicaciones metalmecánicas.
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Date
2025
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Publisher
Universidad de Concepción
Abstract
El presente trabajo aborda el diseño y verificación de un cabezal de corte por chorro de agua con abrasivo (AWJ) integrado a un intensificador hidráulico propio, orientado a empresas metalmecánicas que requieren capacidades de corte avanzadas con una inversión inicial reducida. Se evaluaron distintos rangos de presión y se adoptó 379,21 MPa como condición nominal por su equilibrio entre capacidad de penetración, calidad superficial y vida útil de componentes. El desarrollo combina criterios normativos de recipientes a presión y sellado con modelos analíticos de Lamé, Von Mises y Goodman para dimensionar pistón, émbolo, camisas y tapas, y se valida con simulaciones de elementos finitos en ANSYS, poniendo especial atención en zonas con discontinuidades donde se concentran las tensiones.
Los resultados muestran coherencia entre los cálculos y la simulación, con factores de seguridad adecuados en régimen cíclico y con la localización del punto crítico en la interfase geométrica ya mencionada. Se incorporan medidas de seguridad pasivas: drenaje dirigido para microfugas o falla de sellos, y un tope geométrico que evita impacto del émbolo sobre la válvula de retención ante fallas de detección, privilegiando la integridad de los componentes más sensibles. Para estabilizar el proceso, se adopta un acumulador de 3,2 L (superior al estándar comercial de 2,2 L), reduciendo fluctuaciones de presión y estabilizando el caudal del chorro. En términos económicos, mientras los paquetes comerciales completos (intensificador y dosificador de abrasivo) rondan los $40.000.000 CLP, la fabricación e implementación del cabezal de corte propuesto —incluyendo dosificación para aplicaciones de mediana escala— se estima en torno a $15.000.000 CLP, configurando una alternativa técnicamente viable y costo-efectiva sin comprometer seguridad ni desempeño.
This thesis presents the design and verification of an abrasive waterjet (AWJ) cutting head with a custom hydraulic pressure intensifier, targeted at small and medium metalworking companies seeking advanced cutting capabilities at lower upfront cost. After assessing several pressure ranges, 379.21 MPa was selected as the nominal operating point for its balance between cutting depth, surface quality, and component durability. The methodology combines regulatory criteria for pressure components and sealing with analytical sizing using Lamé, von Mises, and Goodman to design piston, plunger, liners, and covers, and is validated via finite element analysis in ANSYS, with emphasis on superposed geometric discontinuities (U-groove with hole) where stress concentration governs. Results show consistency between analysis and simulation, with suitable safety factors under cyclic service and the critical region confined to the noted geometric interface. Passive safety features are embedded: directed drainage to manage micro-leaks or seal failure, and a geometric stop preventing plunger impact on the check valve in case of sensor failure, thus protecting the most delicate parts. Process stability is enhanced by a 3.2-L accumulator—larger than the typical 2.2-L commercial units—reducing pressure ripple and stabilizing flow. Economically, while complete commercial packages are around $40,000,000 CLP, the proposed cutting head—including an abrasive feeder for medium-scale applications—costs approximately $15,000,000 CLP, offering a technically sound and cost-effective alternative without compromising safety or performance.
This thesis presents the design and verification of an abrasive waterjet (AWJ) cutting head with a custom hydraulic pressure intensifier, targeted at small and medium metalworking companies seeking advanced cutting capabilities at lower upfront cost. After assessing several pressure ranges, 379.21 MPa was selected as the nominal operating point for its balance between cutting depth, surface quality, and component durability. The methodology combines regulatory criteria for pressure components and sealing with analytical sizing using Lamé, von Mises, and Goodman to design piston, plunger, liners, and covers, and is validated via finite element analysis in ANSYS, with emphasis on superposed geometric discontinuities (U-groove with hole) where stress concentration governs. Results show consistency between analysis and simulation, with suitable safety factors under cyclic service and the critical region confined to the noted geometric interface. Passive safety features are embedded: directed drainage to manage micro-leaks or seal failure, and a geometric stop preventing plunger impact on the check valve in case of sensor failure, thus protecting the most delicate parts. Process stability is enhanced by a 3.2-L accumulator—larger than the typical 2.2-L commercial units—reducing pressure ripple and stabilizing flow. Economically, while complete commercial packages are around $40,000,000 CLP, the proposed cutting head—including an abrasive feeder for medium-scale applications—costs approximately $15,000,000 CLP, offering a technically sound and cost-effective alternative without compromising safety or performance.
Description
Tesis presentada para optar al título de Ingeniero/a Civil Mecánico/a.
Keywords
Corte de metales, Corte por chorro de agua, Procesos de manufactura