A study on the interaction of jet with constituent layers of multilayered structure in through kerfing with abrasive waterjets

Abstract

Abstract Abrasive waterjet technology is favored over solid cutting tools for cutting of multi-layered structures in view of its non-contact nature and its ability to cut a wide range of materials. However, the stochastic nature of abrasive water jet (AWJ) interacting with a multi-layered structure (MLS) produces a non-uniform kerf geometry. This non-uniformity depends on the characteristics of jet i.e. jet energy, the duration of interaction of jet with the material, and the nature of material exposed to the jet during cutting. This paper attempts to cover a study that systematically analyses the geometry of kerf generated in MLS and a stack of multiple materials with each material having different mechanical properties. It also covers a study to analyse the role of interfacial adhesive layer on kerf profile variation, and the preferential orientation of multi-layered structure and stacked materials, with its top layer, having an appropriate mechanical resistance (MR), in order to arrive at a strategy to present the structure or a stack of materials to AWJs for producing near uniform kerf profile. Hence, AWJ cutting experiments were carried out over a single- and double- layered structures (SLSs, DLSs) with two different materials such as aluminum (Al), mild steel (MS), which showed a completely different kerf geometry when these materials are stacked in different ways. Stacking of these materials in different ways produced kerf of different geometry not only in the materials but also at their interface. This systematic study enabled to suggest the correct presentation of MLS and also a stack of multiple materials with a suitable material in top layer, to AWJ, for producing near uniform kerf in them. Further, this study also suggested several hypotheses like the importance of relative MR of adjoining layers, critical jet traverse rate, pseudo focusing nozzle, and the choice of layer placement in producing near uniform kerf on MLS and a stack of materials, so as to minimize the efforts in post machining of AWJ cut surfaces. Finally, the relevance of the proposed hypotheses was validated by analyzing the kerf formed over MS-rubber-MS and rubber-MS-rubber configured three-layered structure.