Modelling of abrasive waterjet kerf in a double-layered structure

Abstract

Abrasive waterjets can process multi-layered structures but pose difficulties in producing quality cuts since MLS comprises of layers of materials with heterogeneous/homogenous properties. Stacking sequence of layers and the interface between layers influence kerf characteristics. Kerf geometry in each layer is influenced by a nonlinear structure with non-uniform energy distribution of AWJ. This paper presents a model to predict kerf geometry in a double-layered structure by considering jet characteristics, workpiece properties, jet-workpiece interaction at the layers' interface, and AWJ process parameters. Towards determining the jet's exclusive interaction with each layer, complete kerf profile (CKP) formation is analyzed by considering homogenous materials as constituent layers of Al-MS and MS-Al configurations. The model predicted results are in good agreement with experimental results. The average root mean square error of the kerf profile is less than 0.048 mm, and the mean absolute error is about 12.63% on both configurations. • First attempt to model the kerf cross-sectional profile in double-layered-structures (DLS) with abrasive waterjets (AWJs) • Discretization approach for prediction of the comprehensive kerf cross-sectional profile (CKP) in DLS cut by the AWJs • Prediction of the CKP in DLS considering AWJ process parameters, jet characteristics and workpiece properties • Non-linearity in kerf width at the interface of layers in DLS attributed to jet-workpiece interaction at the interface