A Modeling Study of Metal Cutting With Abrasive Waterjets

Abstract

An experimental and theoretical investigation was conducted to study the cutting of ductile metals with high-velocity abrasive jets. The investigation involved experimental cutting tests, visualization experiments, and model development. Data were generated to study the effects of abrasive-jet parameters on the depth and quality of cuts produced. These parameters included waterjet pressure, waterjet diameter, abrasive material, particle size, abrasive flow rate, traverse rate, and number of passes. The penetration process was found to be cyclic and to consist of more than one cutting regime as the kerf developed. In the first regime, particles impact the kerf wall at shallow angles, and cutting wear occurs; in the second, particles impact at large angles, causing deformation wear. A simplified model was developed to determine the optimum set of parameters for efficient high-quality machining of ductile metals. The model requires further refinement, however, to provide definitive results.