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Linear Abrasive WaterJet Machining (AWJM) tests have been performed on Carbon Fiber Reinforced Plastic (CFRP) in order to have a first reference of the main defects developed onto the machined surface. Delamination has been proved as one of the most critical defects when machining composites or layered materials. In this work this defect and the influence of cutting parameters in its formation have been studied. For this purpose, delamination morphology has been characterized using Scanning Optical Microscope and Scanning Electron Microscope. Additionally, a study of the influence of cutting conditions and material removal mechanisms involved has been achieved.

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Scanning electron microscopy (SEM) has been used to identify and analyse the secondary adhesion effect precursors formed during the dry drilling processes of Ti-6Al-4V alloy over the rake face and flute of the drilling tools. Subsequent analysis with energy dispersive spectroscopy (EDS) was enabled to distinguish its compositional characteristics. Thus, according to the EDS obtained data, a stratified multi built-up layer (MBUL) composed by TiOxis formed over the rake face of the tool. Furthermore, this multi-layer adhered allows initially the built-up edge (BUE) development close to the edge of the tool by a mechanical adhesion mechanism. In a second step, it is responsible for the formation of a thicker secondary BUL which avoids the chip flow, and it provokes the tool collapse. These mechanisms are different from those observed in the dry machining of other alloys such as steels, nickel-based alloys, or aluminium alloys.