Prediction model of depth of penetration for alumina ceramics turned by abrasive waterjet—finite element method and experimental study

Abstract

Many finite element (FE) models for the impacts of ultrahigh-velocity micro-particles on ductile materials have been developed in the recent years. However, few FE models on brittle materials were found from the literatures. This paper presented an attempt to model the ultrahigh-velocity (417–528 m/s) impact process for alumina ceramics. The methodology involved the FE method analysis to estimate the volume of material removal based on the Johnson–Holmquist ceramic material (JH-2) model. Subsequently, the depth of penetration (DOP) on various abrasive waterjet (AWJ) turning parameters was predicted by the FE models and derived mathematical equations. The final depths of penetration predicted by the FE models were found to be in good agreement with the experimental results. The average relative error between the predicted and experimental results was lower than 15 %. Furthermore, the preliminary mechanism of ceramic material removal was analyzed from the FE models. Under ultrahigh-velocity impact, the ceramic material removal stemmed from the initiation and propagation of the cracks. The large-scale ceramic material removal was caused by the crack coalescence. Thus, the DOP on AWJ turning process can be effectively predicted by the FE models. Expectantly, this paper will supply a guidance to select a proper method for predicting the AWJ turning process.