Improvement of a low-cost water jet machining intensifier using reverse engineering and redesign methodology

• Published in: Journal of engineering design 2007-02, Vol.18 (1), p.13-37
• Main Authors: Geren, N., Bayramoğlu, M., Eşme, U.
• Format: Article
• Language: English
• Subjects: Cutting tools; Design; Design engineering; High pressure; Intensifier design; Machinery; Methods; Product design; Product development; Reverse engineering and redesign; Sealing; Water-jet cutting
• ISSN: 0954-4828; 1466-1837
• DOI: 10.1080/09544820600650928

Water jet machining (WJM) systems are quickly gaining wide industrial acceptance for cutting metallic and non-metallic materials in complex shapes. However, WJM systems are not used extensively by small-scale and medium-scale industries due to their high cost. There is no commercially available WJM system to meet the requirements of small-scale industries. In order to satisfy their demand, a low-cost first alpha-prototype WJM system has been previously developed using conventional design techniques. The intensifier, which is the key component of a WJM, is mainly responsible for the high cost. Therefore, this study concentrates on the redesign of the intensifier used in the prototype. Technical and economical requirements, as well as the main principle used on the double-acting intensifiers, constitute strong design constraints that do not permit drastic modifications using conventional design techniques. A novel redesign methodology, developed by Otto and Wood, provides systematic approach for the product development that matches customer needs. Therefore this methodology has been modified and used to improve the existing prototype. The methodology consists of a 10-step process with four primary phases. Most of the design enhancements on the components of the prototype WJM system have been achieved through the use of the redesign methodology compared with conventional design methodology.