STUDY ON MESH DEPENDENCE OF CUTTING ZONE DIMENSIONS PREDICTION DURING ABRASIVE WATERJET MACHINING

Abstract

Abrasive Waterjet Machining is a non-conventional material removal process, preferred to be used for the cutting of difficult-to-cut materials, due to its ability to remove material without the use of a tool and without causing heat affected zones. Experimentally, monitoring the phenomena taking place in the cutting area is very difficult, due to various reasons such as the high speed of the particles and the obstruction due to the water stream. Thus, a simulation approach, based on experimental data, is required in order to be able to explain these phenomena. In this work, a 3D thermo-mechanical Finite Element model is presented with realistic representation of the positioning of discrete abrasive particles and the dependence of cutting zone dimensions on the mesh size is investigated. After simulation, results are compared to experimental results, mesh independence study is conducted and finally, conclusions on the optimum mesh size are drawn and observed process characteristics are discussed.