Correction of Shape Error at Cut-In and Cut-Out Points in Abrasive Waterjet Cutting of Carbon Fiber Reinforced Polymer (CFRP)

Abstract

This paper presents a solution aimed at enhancing the accuracy of abrasive waterjet cutting (AWJC) for the processing of carbon-fiber-reinforced polymers (CFRP). Processing CFRP with high accuracy and good surface quality in a short processing time is a difficult task. One crucial problem is the occurrence of shape errors, overcuts, at the cut-in and cut-out point during the cutting process. Shape errors have the potential to create mechanical stress concentrators, which can result in structural failures and compromise the integrity and reliability of components. The primary objective of this study was to gain a comprehensive understanding of the formation mechanism underlying the shape error. The observed shape error is closely associated with both the lead-in/lead-out strategies employed and the process parameters selected. The experimental investigation focused on two commonly used strategies for CFRP cutting: lead-in/lead-out in arc and lead-in/lead-out in line. In order to minimize shape errors, this study proposed a correction method that offers a set of recommendations for selecting the appropriate lead-in/out strategy and a suitable combination of process parameters. Additionally, a mathematical model has been developed to determine the depth of the shape error. The conclusions drawn from this study have been successfully validated through industrial applications.