Abrasive Waterjet Cutting of Clad Composite for Achieving Minimal Cut Quality Difference Between Constituent Layers

Abstract

Clad composites have emerged as a suitable choice to augment the industrial needs due to having a combination of different properties. The accurate cutting is challenging due to the heterogeneous nature of the composite. Conventionally, thermal cutting (plasma/gas) techniques are commonly employed which provide poor cut quality, deeper heat affected zones and demand additional finishing operations. Therefore, this research evaluates the potential of abrasive water jet cutting (AWJC) as a proficient substitute for the cutting of stainless-clad-steel composite in terms of surface quality. However, it is difficult to produce a similar level of surface finish at both the layers because the constituent layers have different mechanical properties. The effect and significance of four important AWJC parameters on cut quality are examined through statistical analyses. Optical and scanning electron microscopic analyses are further provided as evidence of the reported results. Optimal settings are also developed using a weighted signal-to-noise ratio technique which can provide minimal roughness at each layer. Moreover, using the optimal settings, a similar level of surface finish has been achieved for both the layers with a difference of just 0.03 µm between the constituent layers.

Research Regarding the Dimensional Precision of Electrical Steel Strips Machined by Waterjet Cutting in Multilayer Packages

“… Initial experimental trials were performed in order to identify the process limitations regarding the most important influence factors, waterjet traverse speed and number of layers per package to be cut at once. These two factors are also the easiest to be small gaps between layers In the cases of cutting multilayer packages when the sheets are completely separated, the behavior of the material is different compared to the AWJM cutting of multilayer composite structures when the layers are welded or glued together [41]. The fixing method on the machine tool is very important because it is the single method to keep the layers as closed as possible without gaps between layers.…”

“…The sheet strips, especially the ones obtained from coils, have their own flatness deviation, and when they are layered in a package and fixed together only on the lateral areas, small gaps could remain between the layers in the cutting area (Figure 11). In the cases of cutting multilayer packages when the sheets are completely separated, the behavior of the material is different compared to the AWJM cutting of multilayer composite structures when the layers are welded or glued together [41]. The fixing method on the machine tool is very important because it is the single method to keep the layers as closed as possible without gaps between layers.…”

Study on flame cutting process of thick stainless-clad steel

“…There are generally three basic types of processes that can be used to cut thick stainless-clad steel: waterjet, mechanical, and thermal cutting (plasma, flame, and EDM cutting). Kashif Ishfaq et al studied the optimized process for waterjet cutting of stainless steel and carbon steel composites [1,2]; Nadeem Ahmad Mufti et al studied the main process parameters affecting the cutting rate of EDM cutting of stainless steel and carbon steel composites and obtained optimized parameters [3]. Rakhimyanov et al studied a high-precision plasma process for cutting iron and aluminum alloys [4,5].…”

Probabilistic investigation of geometric responses in Wire EDM machined complex-shaped profile: A machine learning based approach

“…As a result, the usage of advanced machining technologies has increased, as these processes encourage non-contact machining. [1][2][3][4][5] Wire electric discharge machining is an advanced machining technique which is extremely popular in industries for producing parts with high accuracy and precision. 6,7 However, due to deflection of the wire, such accuracy and precision cannot be attained in small-arced corners and curved profiles, but limited to straight cuts only.…”