Surface quality and kerf width prediction in abrasive water jet machining of metal-composite stacks

Pahuja, Rishi; Ramulu, M.; Hashish, M.

doi:10.1016/j.compositesb.2019.107134

Cited by 65 publications

(46 citation statements)

References 29 publications

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“…It is necessary to remember that there is currently no article that analyzes the taper defect in abrasive waterjet machining of thermoplastic composite materials. Some of reviewed literature [22,24,27] shows values close to the range obtained in this experiment, although some specific kerf taper values are different. It must be taken into account that the composites used in the other articles are made of a thermoset matrix.…”

Section: Resultssupporting

confidence: 84%

“…The emphasis in this article is on the independent treatment of such areas. Several authors [17,22,24,27] calculate the kerf taper defect without taking this indication into account. This could cause the kerf taper values to be altered by the rounding radius generated on the top surface of machined material.…”

Section: Resultsmentioning

confidence: 99%

“…The formation of the zone known as the initial damage region (IDR) is due to the erosive action of abrasive particles, which produce a combination between this defect and the taper angle. In this way, the evaluation of upper width (Wt) can be increased due to this erosive action, giving rise to a dispersion in the evaluated taper, as observed in results shown in references [22][23][24].…”

Section: Introductionmentioning

confidence: 87%

“…Three main parameters, which include hydraulic pressure, feed rate, and abrasive mass flow, were employed to determine their influence of the kerf taper generated. These parameters were designated based on the limitations of the CNC machine used, as well as the levels most employed in reviewed literature [17,22,24,31,32]. Also, they were converted into three different levels (-1, 0, 1) that represent minimum, central, and maximum values, respectively (Table 2).…”

Section: Reinforcementmentioning

confidence: 99%

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Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

et al. 2019

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Carbon fiber-reinforced thermoplastics (CFRTPs) are materials of great interest in industry. Like thermosets composite materials, they have an excellent weight/mechanical properties ratio and a high degree of automation in their manufacture and recyclability. However, these materials present difficulties in their machining due to their nature. Their anisotropy, together with their low glass transition temperature, can produce important defects in their machining. A process able to machine these materials correctly by producing very small thermal defects is abrasive waterjet machining. However, the dispersion of the waterjet produces a reduction in kinetic energy, which decreases its cutting capacity. This results in an inherent defect called a kerf taper. Also, machining these materials with reduced thicknesses can increase this defect due to the formation of a damage zone at the beginning of cut due to the abrasive particles. This paper studies the influence of cutting parameters on the kerf taper generated during waterjet machining of a thin-walled thermoplastic composite material (carbon/polyurethane, C/TPU). This influence was studied by means of an ANOVA statistical analysis, and a mathematical model was obtained by means of a response surface methodology (RSM). Kerf taper defect was evaluated using a new image processing methodology, where the initial and final damage zone was separated from the kerf taper defect. Finally, a combination of a hydraulic pressure of 3400 bar with a feed rate of 100 mm/min and an abrasive mass flow of 170 g/min produces the minimum kerf taper angle.

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Section: Resultssupporting

confidence: 84%

Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 87%

Section: Reinforcementmentioning

confidence: 99%

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Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

et al. 2019

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“…Li et al [ 15 ] studied deformation of stainless steel 304 and its mechanical properties after AWJ processing by using several methods. Pahuja et al investigated the behaviour of the abrasive water jet during its passage through a system of plates made from various kinds of materials [ 16 ]. Their findings are very important for certain industrial applications, namely in aerospace.…”

Section: Introductionmentioning

confidence: 99%

Influence of Material Structure on Forces Measured during Abrasive Waterjet (AWJ) Machining

et al. 2020

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Material structure is one of the important factors influencing abrasive waterjet (AWJ) machining efficiency and quality. The force measurements were performed on samples prepared from two very similar steels with different thicknesses and heat treatment. The samples were austenitized at 850 °C, quenched in polymer and tempered at various temperatures between 20 °C and 640 °C. The resulting states of material substantially differed in strength and hardness. Therefore, samples prepared from these material states are ideal for testing of material response to AWJ. The force measurements were chosen to test the possible influence of material structure on the material response to the AWJ impact. The results show that differences in material structure and respective material properties influence the limit traverse speed. The cutting to deformation force ratio seems to be a function of relative traverse speed independently on material structure.

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The influence of hole quality on mechanical behavior and strain distribution of open‐hole CFRP laminates subject to different machining processes

Jiang

2022

Polymer Composites

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Machining process is generally required for cutting composite material of structural components prior to final assembly in aerospace industry. This study aimed to investigate surface quality and mechanical behavior of open‐hole composite laminates following different machining processes including abrasive waterjet cutting, high power fiber laser machining, conventional drilling and ultraviolet laser machining. Hole quality was quantified for further understanding the correlation between surface damage and mechanical behavior. Experimental results demonstrated that the hole geometrical accuracy and mechanical property were highly dependent on the machining methods. Digital image correlation technique was implemented to capture the strain distribution and strain evolution around open holes during tensile loading. Machining methods exhibited significant impact on εitalicyy, εitalicxx, and εitalicxy strain levels around hole edges, while limited influence on strain distribution patterns. εitalicyy and εitalicxx concentrated in the regions consisting of fibers perpendicular to and along the loading direction respectively, and shear strain εitalicxy featured with X shape around hole edge.

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Surface quality and kerf width prediction in abrasive water jet machining of metal-composite stacks

Cited by 65 publications

References 29 publications

Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

Kerf Taper Defect Minimization Based on Abrasive Waterjet Machining of Low Thickness Thermoplastic Carbon Fiber Composites C/TPU

Influence of Material Structure on Forces Measured during Abrasive Waterjet (AWJ) Machining

The influence of hole quality on mechanical behavior and strain distribution of open‐hole CFRP laminates subject to different machining processes

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