Enhancing abrasive waterjet trepanned hole geometry using a through-kerf prediction model informed sequential machining

Abstract

The hole-making process is essential in manufacturing. Conventional trepanning ensures accuracy, it faces challenges like heat effects, tool wear, and residual stress. Conversely, abrasive waterjet (AWJ) trepanning offers versatility in hole sizes and materials; it introduces geometrical deviations. This study leverages the benefits of AWJ trepanning and conventional milling (CM) to improve hole geometric accuracy. Post-AWJ trepanning, CM informed with a predicted hole geometrical deviation for correction using a through-kerf profile model (≤ 3.3 % error) proposed based on the hypothesis (validated, 12 %−15 % error) that gradually evolved kerf geometry dictates the hole geometrical deviations. The combined approach significantly minimizes geometrical errors.