Modelling of Abrasive Water Jet Cutting with Controlled Depth for Near-Net-Shape Fabrication

Efficient abrasive water jet milling for near-net-shape fabrication of difficult-to-cut materials

“…Since the feed speed v f (d K ) can be adjusted very precisely, this parameter is tested to ensure a homogeneous jet at all times. In the previous investigations [4], the use of an angle of cut α c for a milling operation has shown a distinct influence on the kerf parameters. Comparable effects must be expected for kerfs with variable kerf depths d K (x) as well.…”

“…These are, for example, the independence of the tool wear from the workpiece material, the absence of repercussions of the material surface on the cutting ability of the AWJ and the possibility to cut almost all kinds of materials brittle [1] and ductile [2]. Thus, AWJ is a promising technology, particularly to manufacture difficultto-cut materials such as metal matrix composites (MMC), nickel base alloys [3], titanium aluminides [4], ceramics, ceramic matrix composites (CMC) [5] or carbon fibrereinforced polymers (CFRP) [6]. Since the application of such materials is continuously increasing due to the demands of light weight design and efficiency requirements, the AWJ technology has attracted further attention and the market is continuously growing over the last years.…”

“…In order to increase the efficiency of the AWJ milling process, the superposition of two kerfs, cut from different sides of the workpiece (Fig. 1c), was suggested [14] and studied in detail by Faltin [15] and in previous investigations regarding the modelling possibilities [4], the implementation [16] and the cost-effectiveness [17] of the approach.…”

“…Faltin [15] demonstrated the feasibility of the approach and provided fundamental knowledge for its application. Furthermore, a model has been introduced to effectively design these AWJ milling operations in a previous work [4]. Following this approach, the AWJ milling operations can be designed and predicted by the use of a power coefficient c p and three coefficients c 1 to c 3 for the development of a kerf over the number of passes z.…”

“…Both the modelling study [4] and the analysis by Faltin [15] consider only the cutting of constant kerfs depths (Fig. 1c).…”