Abstract
Multi-particle velocities and trajectories in abrasive waterjet machining are of great value to understand the particle erosion mechanism involved in the cutting process. In this paper, the whole-stage simulation model is established from the high-pressure water and abrasive particles entering the nozzle to the mixed abrasive jet impacting the workpiece based on the SPH-DEM-FEM method. Comparing the simulation results with the experimental results under different process parameters, the capability of the proposed model is systematically validated. The model is applied to study the mixing and accelerating process of abrasive particles, and the results show that a speed difference is existed between the water and abrasive particles after being ejected from the nozzle. In addition, the nozzle wear pattern is also analyzed carefully. It is discovered that the most serious wear happened at the junction of the mixing chamber and the focusing tube. And the focusing tube wear is uneven and spreads downward.
Highlights
Abrasive waterjet machining (AWJM) is a typical high-energy fluid jet machining technology
The whole-stage simulation model is established from the high-pressure water and abrasive particles entering the nozzle to the mixed abrasive jet impacting the workpiece based on the smoothed particle hydrodynamics (SPH)-discrete element method (DEM)-FEM method
The SPH-DEM-FEM method is adopted to establish the AWJM simulation model of the whole-stage process from the jet beam and the abrasive stream being injected into the nozzle to mixed abrasive water jet impacting the workpiece surface
Summary
Abrasive waterjet machining (AWJM) is a typical high-energy fluid jet machining technology. The abrasive particles are entrained within the high-velocity waterjet and accelerated inside the nozzle head [1]. It offers superior processing performance, such as negligible heat-affected zone, low specific cutting force, and high flexibilities over other conventional (e.g., milling, turning) or non-conventional machining techniques (e.g., electrical discharge machining, laser). It is being widely and increasingly utilized to machine hard-to-cut materials like engineered ceramics [2], composites [3], and high strength steel [4], for instance. The cutting qualities, especially the kerf geometrical characteristics and surface integrities, are susceptible to energetic, kinematic, and constructive parameters, which result in the difficulties of controlling the AWJM process
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