Accuracy and surface quality of abrasive waterjet machined CFRP composites

Abstract

The use of carbon fiber-reinforced composites is increasing today since they have an excellent weight-to-mechanical properties ratio. Traditional machining of this material is difficult. Abrasive water jet machining (AWJM) is an advanced non-traditional material removal process that can machine hard-to-cut materials. The process is widely used in aerospace, marine, and automotive industries. However, it encounters several challenges when cutting carbon fiber reinforced polymers (CFRP). The present work aims to study the characteristics of AWJM of CFRP laminates. Detailed experimental investigations are conducted to explore the effect of traverse feed and standoff distance (SOD) on top kerf width, bottom kerf width, kerf angle, profile area, volumetric removal rate, and the average surface roughness, and jet deviation factor. Repeatability tests are also used to assess the kerf dimensional accuracy and surface roughness tolerance achieved by AWJM of CFRP laminates. Results showed that the surface roughness increases along with the cut thickness, especially at large traverse feed and SOD. Both the kerf taper angle and the volumetric removal rate increase with traverse feed and SOD.