A novel abrasive water jet side machining method for curved surface profile

Abstract

In the domain of hard and brittle material machining, Computer Numerical Control (CNC) machining processes frequently face challenges like tool wear and material fragmentation. Abrasive Water Jet Machining (AWJM) offers a viable alternative to conventional CNC machining. Nevertheless, conventional AWJM techniques are inadequate for the surface machining as the entire jet beam acts upon the workpiece to achieve cleaning or separating functions. The study introduces a novel Abrasive Water Jet (AWJ) side cutting method that employs part of the jet beam for machining, which is capable of delivering high-quality and efficient AWJ surface processing and curvature machining. The mechanism of side cutting is explored using theories related to elastic collision and solid damage, based on which the machining profile prediction model is built. Then, relying on the side-cutting characteristics and the analysis of the contact relationship between the jet beam and the workpiece, an AWJ side cutting process planning method is developed, in which an optimization algorithm is employed to iteratively identify the optimal jet cutting path, thereby achieving an efficient process for surface profiling. Both computer simulation and physical cutting experiments of the proposed method have been conducted, and the results provide initial validation for the effectiveness and benefits of the proposed method.