Analytical Modeling and Experimental Study on Machining of CFRP/Ti Stacks with Submerged Abrasive Waterjet Machining

Abstract

Abstract The research includes analytical modeling and experimental study on precision machining of hybrid composite stacks with Submerged Abrasive Waterjet Machining (SAWJM) process. The analytical model predicts the rate of material removal during the SAWJM process. An in-house fabricated SAWJM setup is used to machine stacks of Titanium and Carbon Fiber Reinforced Polymer (CFRP). The study compares critical process parameters including grit size, machined cavity size, stand-off distance, and kerf angle in SAWJM and Abrasive Waterjet Machining (AWJM) processes are evaluated. It was found that SAWJM process has the capability of effectively machining CFRP/Titanium composites with high precision. The machined surface did not show any cracking and delamination about the edges and is free of thermal stresses. In this study, the standoff distance and the size of the abrasive grains have a noteworthy influence on the machining process. The cavities machined on both CFRP and titanium during SAWJM process are smaller and more circular than that produced during AWJM process. Both analytical model predictions and experimental results match within 10 % error. The results of this study provide a deeper insight into the precision machining of hybrid composite stacks.