Abrasive Water Jet Research Articles

Fragmentation characteristics of abrasive particles for hard rock drilling with waterjet energy parameter

The use of abrasive waterjets (AWJs) for rock drilling offers advantages in urbanized areas, locations that are vulnerable to damage, and piling operations. However, the overall operational cost of AWJ systems remains high compared to that of conventional drilling methods, which constrains the long-term industrial application of AWJs. For instance, the abrasive costs account for over 60% of the total process cost, but the recycling of abrasives remaining after drilling could significantly reduce machining costs. In this study, the post-impact characteristics of abrasives were explored, aiming to enhance their recyclability. The physical properties and particle distribution of used abrasives vary depending on the jet energy, ultimately affecting their recyclability and recycling rate. The particle properties of used abrasives (particle size distribution, particle shape, and mean particle size) were compared under different waterjet energy variables (standoff distance (SOD) and water pressure) and test conditions (dry and underwater). Furthermore, the collision stages of the abrasive particles within a waterjet system were classified and analyzed. The results revealed that abrasive fragmentation predominantly occurred due to internal collisions within the mixing chamber. In addition, an attempt was made to optimize the waterjet parameters for an economical and efficient operation. The findings of this study could contribute to enhancing the cost-effectiveness of AWJ systems for rock drilling applications.

Effect of abrasive volume fraction on energy utilization in suspension abrasive water jets based on VOF-DEM method

Effect of abrasive volume fraction on energy utilization in suspension abrasive water jets based on VOF-DEM method

Mechanism and prevention of coal bursts in gob-side roadway floor under thick and hard roof in the deep mining area of Ordos

The complex stress environment in deep roadways, often exacerbated by thick and hard strata, frequently precipitates coal bursts, posing significant safety hazards. This paper investigates the mechanisms and preventive methods for coal bursts in the gob-side roadway floor (GSRF) under thick and hard roof in the Ordos region, China. First, the stress-distributing characters of GSRF were analyzed then a stress calculation formula was derived. A mechanical model was developed to determine the critical stress for buckling failure of the roadway floor strata. Criteria for the bursting instability of GSRF were then established. The lateral static load from the adjacent gob, the advancing static load from the working face, and the disturbance load from overlying thick and hard roof fractures combine to transmit high loads and energy to the roadway floor via the “roof → rib → floor” pathway, causing increased stress concentration and energy accumulation. When the conditions satisfy the criteria for bursting instability, coal bursts can occur on the roadway floor. To mitigate dynamic load disturbances, the paper proposes roof regional fracturing and abrasive water jet axial roof cutting. Hydraulic reaming of gutters in the roadway ribs and deep hole blasting at the roadway bottom corners are offered to alleviate the static loads on the surrounding rock. The implementation of targeted prevention measures for dynamic and static loads effectively reduces coal bursts in GSRF. These findings offer an example of preventing and controlling coal bursts in other mines of the Ordos region with comparable geological conditions.

Preliminary investigation on spent garnet as a novel supplementary cementitious material

The escalating global demand for cement, a fundamental material in infrastructure development, has exacerbated environmental challenges, particularly through significant carbon dioxide (CO₂) emissions, which account for approximately 8.3 % of global anthropogenic CO₂ output. This research explores the potential of spent garnet powder, a byproduct of abrasive water jet machining, as a sustainable supplementary cementitious material (SCM) to mitigate these impacts. The spent garnet powder, characterized by a high concentration of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃), and iron oxide (Fe₂O₃), was subjected to rigorous analysis. X-ray Fluorescence (XRF) confirmed its chemical suitability for pozzolanic applications, while laser particle size analysis revealed a finer granulometry relative to Ordinary Portland Cement (OPC), which is advantageous for enhancing pozzolanic reactivity. Scanning Electron Microscopy (SEM) demonstrated the angular and irregular morphology of the garnet particles, which is conducive to improved interfacial bonding within the cement matrix. X-ray Diffraction (XRD) identified active mineral phases that are critical for promoting pozzolanic reactions, and Thermogravimetric Analysis (TGA) demonstrated the material’s superior thermal stability, with minimal decomposition at elevated temperatures. Fourier Transform Infrared Spectroscopy (FTIR) identified strong silicon-oxygen (Si-O) and aluminum-oxygen (Al-O) bond structures, indicative of robust pozzolanic potential. The Strength Activity Index (SAI) and Frattini tests further substantiated the pozzolanic activity, revealing that a 10 % replacement of OPC with SGP not only enhances compressive strength but also meets the stringent requirements of ASTM C618. Additionally, the economic analysis underscores the cost-effectiveness of utilizing spent garnet powder, presenting a viable strategy for reducing both production costs and CO₂ emissions in the cement industry. This study conclusively positions spent garnet powder as a highly promising supplementary cementitious material, with significant implications for advancing sustainable construction practices and reducing the environmental footprint of cement production.

An unresolved SPH-DEM model for simulation of ductile and brittle surface erosion by abrasive water-jet (AWJ) impact

The abrasive water-jet (AWJ) erosion process involves the complex interaction between fluid medium, abrasive particles and solid material, which brings great challenges to the establishment of numerical model. Because traditional grid-based methods are not suitable for the problems of local deformation and material removal, the meshfree method smoothed particle hydrodynamics (SPH), based on the unresolved coupling and the discrete element method (DEM), is adopted to establish the model for AWJ study. The fluid medium is treated as a weakly compressible viscous liquid, the solid material is treated as an elastic-plastic material, and the abrasives are treated as rigid bodies. The fluid and solid phases are discretized with SPH particles, and the abrasives are described with DEM particles. The Johnson-Cook (J-C) and Johnson-Holmquist-II (JH-2) constitutive models are used to describe the stress-strain behavior of ductile and brittle materials, respectively. The effectiveness of the numerical model is further verified by AWJ impact experiments. The plastic deformation and cumulative failure characteristics of ductile materials, and the crack formation and propagation characteristics of brittle materials are systematically analyzed. The results provide insight for the AWJ research and lay a foundation for investigation of other complex fluid-particle flow in a numerical way.

Machining Efficiency and Property Change Analysis of Ti-6Al-4V Alloy Processed by Abrasive Water Jet Machining

Machining Efficiency and Property Change Analysis of Ti-6Al-4V Alloy Processed by Abrasive Water Jet Machining

Efficiency of machining polymer, marble and steel materials at abrasive water jet cutting

In recent decades, waterjet cutting technology has become widespread across various industries worldwide, ranging from automotive and insulation manufacturing to aerospace. Concurrently, it’s increasingly important for the applied technological parameters to be efficient and cost-effective. This necessitates the appropriate selection of key technological parameters. In this article, we examined the efficiency of abrasive waterjet cutting in three different material qualities: polymer, ceramic, and steel. The article explores the relationship between cutting depth—considered as one widely accepted indicator of efficiency—and technological parameters, drawing conclusions regarding the machinability of various materials.

Geometrical Characteristics of Kerf width on Titanium Alloy by Abrasive Water Jet Machining

Geometrical Characteristics of Kerf width on Titanium Alloy by Abrasive Water Jet Machining

Research on high‐pressure abrasive water jet slotting and pressure relief technology for hard rock roof

AbstractTo solve the problem of severe rock pressure near coal mining face tunnels, a high‐pressure abrasive water jet slotting and roof breaking pressure relief technology is proposed. First, the laneway deformation mechanism and the process of hard rock slotting using high‐pressure abrasive water jets under long‐distance cantilever conditions are analyzed, and the crack initiation conditions of roof strata are obtained. Second, slotting tests under different slotting pressures, nozzle diameters, abrasive particle sizes and slotting times were carried out, and the slotting parameters of a high‐pressure abrasive water jet on a typical roof rock were obtained. Finally, industrial application was carried out in the 81,403 working face of Huayang No.1 Mine. After the hydraulic roof slotting measures were implemented in the test area, the maximum axial force of the anchor cable was reduced to 67 kN, which was 35.5% lower than that of the comparison. The average stress of the coal seam was 15 MPa, which was approximately 25% lower than that of the comparison. The deformation of the tunnel in the experimental area was significantly controlled, with an average movement of 30.0% toward the roof and floor of the tunnel and an average movement of 23.2% toward the two sides of the tunnel. Compared with the movement in the comparison section, the movement toward the roof and floor of the laneway was 42.3% lower, and the movement toward the two sides was 38.2% lower. The industrial application results show that high‐pressure abrasive water jet roof slotting and pressure relief technology can cut off the stress transmission path between the roof rock on both sides, effectively improve the stress state of the surrounding rock of the laneway, reduce the deformation of the roof, floor and two sides of the working face in the later stage of the mining laneway.

Experimental study on optimization of abrasive water jet process parameters

Abstract In order to improve the mining speed of coal mine roadway and fundamentally solve the problem of mining imbalance, the abrasive water jet technology is used to cut rocks in front of mechanical tools to achieve efficient improvement of coal mine roadway mining efficiency. Based on the existing high pressure pure water jet test equipment, the abrasive water jet test platform was built, and the uniaxial compressive strength of soft and hard rock was obtained by testing the rock mechanical properties. The effect of jet pressure, target distance, transverse velocity and jet impact Angle on rock cutting is studied by using control variable method. According to the single factor test analysis, L16 (44) four-factor four-level orthogonal test analysis table is selected to carry out orthogonal tests on granite and sandstone respectively. The results of range analysis and variance analysis show that the main and secondary relationships of abrasive water jet factors are as follows: transverse velocity > jet pressure > jet inclination > target distance. The optimal jet parameters are when jet pressure is 40 MPa, target distance is 5mm, transverse velocity is 2mm/s and jet inclination is 10°.

The Abrasive Water Jet Cutting Process of Carbon-Fiber-Reinforced Polylactic Acid Samples Obtained by Additive Manufacturing: A Comparative Analysis

Carbon-fiber-reinforced polymer (CFRP) composites are widely used across industries due to their enhanced strength and stiffness properties. Fused deposition modeling (FDM) enables the cost-effective production of polymer samples, such as carbon-fiber-reinforced PLA (CFR-PLA). However, CFRP’s hardness and anisotropic nature present significant challenges in conventional machining, including rapid tool wear and thermal sensitivity. Consequently, abrasive water jet machining (AWJM) has proven to be an effective alternative for machining CFRP materials, offering benefits such as reduced tool wear, minimized thermal damage, and improved cutting quality. This study focuses on a comparative analysis of the effects of AWJM parameters on PLA and CFR-PLA samples, specifically to evaluate the influence of carbon fiber reinforcement on machining performance. The findings highlight the critical role of reinforcements in machining behavior. The results suggest that optimizing cutting parameters significantly reduces taper formation and improves machining accuracy. In particular, adjustments to process parameters resulted in lower taper angles and reduced surface roughness in the cutting zones of the CFR-PLA samples.

Influence of brown algae filler and process parameters on the surface roughness and MRR of jute fiber polymeric composite machined by abrasive water jet

Traditional manufacturing of polymeric composite leads to delamination. Implementing abrasive water jet machining (AWJM) presents a sustainable solution for shaping the polymeric composites, thereby eliminating the need to dispose of chemically contaminated waste. Brown microalgae, commonly found in aquatic environments, serve as viable additives for enhancing the properties of polymeric composites. This study entails the polymeric composite reinforced with jute fiber fabricated by modulating the weight percentages of brown algae powder by 0, 3, and 6 wt.% utilizing the hand layup procedure. The composites were formed and subsequently subjected to drilling by AWJ machining filled with brown algae. The experimental investigation was done to analyze the effect of AWJ parameters: water jet pressure (WJP), traverse speed (TS), and stand-off distance (SoD)—on the material removal rate (MRR) and average surface roughness ( Ra). Orthogonal Array L27 experimental results revealed that polymeric composite reinforced with jute fiber containing 3 wt.% of brown algae exhibited the highest MRR, with an increase of up to 12% compared to other samples. Additionally, these composites demonstrated a significant reduction in surface roughness, reaching up to 8% when compared to alternative samples. Utilizing the Taguchi-based ANOVA method facilitated a systematic exploration and identification of influential factors impacting both MRR and Ra in AWJ machining. Notably, the WJP and SoD emerged as key factors significantly influencing both MRR and Ra.

Analysis and optimization of abrasive waterjet dressing parameters for surface texturing of diamond grinding wheels

With the development of ultra-precision machining technology, the grinding performance of diamond grinding wheels has put forward higher requirements. In this study, a new method of dressing diamond grinding wheels using abrasive waterjet (AWJ) technology is proposed to address the issues of workpiece damage and wheel clogging that occur when grinding difficult-to-machine materials with conventional diamond grinding wheels. The main process parameters were determined based on the theoretical model for dressing diamond grinding wheels using AWJ. The response surface methodology (RSM) and the backpropagation artificial neural network (BP-ANN) were employed to establish regression models between process parameters and microgroove characteristics. A comparison was performed to evaluate the prediction performance of both RSM and BP-ANN. The results indicated that both approaches BP-ANN and RSM are powerful tools for predicting microgroove characteristics. This work provides theoretical guidance for texturing diamond wheels surface.

Low temperature machining advantages for sintered NdFeB magnets: A comparative experimental study of WAWJ with laser and WEDM

Sintered NdFeB magnets exhibit excellent magnetic properties and high reliability, making them widely used in fields such as new energy vehicles and electronic communications. However, NdFeB magnets have a low Curie temperature and poor thermal stability. Common machining methods such as laser cutting and EDM (Electrical Discharge Machining) often involve cutting temperatures in the hundreds or even thousands of degrees Celsius, leading to defects such as melting and cracks on the magnet surface. These defects degrade the surface quality and magnetic properties of the magnet. To avoid thermal damage to the magnet during processing, WAWJ (Wet Abrasive Waterjet) cutting was employed on sintered NdFeB. Experimental results indicate that at an ambient temperature of 4.5 °C, the maximum cutting temperature remains below 50 °C, with an average cutting temperature below 25 °C. No heat-affected zones or oxidation layers are exhibited on the cutting surface of the magnet. Jet pressure is identified as the primary factor influencing the maximum cutting temperature, accounting for 96.13 %. With jet pressure increasing from 200 MPa to 280 MPa, the maximum cutting temperature rises from 38.7 °C to 47.9 °C. Furthermore, to validate the necessity of low-temperature cutting for NdFeB magnets, WEDM (Wire Electrical Discharge Machining) and laser cutting were employed on sintered NdFeB magnets. The cutting surfaces of both methods exhibit defects such as cracks, craters, and melting. Compared to the original magnet surface, no significant changes in elemental content were observed on the WAWJ-cut surface. Under high-temperature conditions, the oxidation rate increased, leading to a 18.9 % and 19.8 % increase in oxygen content on the WEDM and laser machined surfaces, respectively. Some neodymium (Nd) and iron (Fe) elements exist in the form of oxides such as FeO and Nd2O3, resulting in loss of magnetism. Moreover, the presence of oxides reduces the continuity of magnetic phases, adversely affecting the magnetic properties of the magnet.

A novel assessment study of surface integrity for nickel-based superalloy milled by abrasive waterjet considering the abrasive embedding

A novel assessment study of surface integrity for nickel-based superalloy milled by abrasive waterjet considering the abrasive embedding

Effect of impact angle on hot corrosion resistance of abrasive water jet peened Ti-6Al-4V alloy

The effect of peening angle (10° to 40°) on NaCl induced hot corrosion behavior of Ti-6Al-4V alloy was evaluated at 750 °C for 100 h. Peening at higher impact angles progressively increases the surface roughness, number of sub-grains, magnitude of compressive residual stresses and hardness of the alloy. During hot corrosion, the surfaces of Ti-6Al-4Al, irrespective of the peened condition, develops oxide scales that contain oxides of Ti, Al and V. Hot corrosion rate, measured in terms of rate of mass gain and the rate constant, Kp, was highest for the unpeened alloy but decreased for surfaces subjected to AWJ peening. Surfaces peened at increasing impact angles have smaller mass gain rate and the one peened at the impact angle of 30° exhibited the lowest corrosion rate and a lowest Kp of ~0.08 mg2/cm4/h. The surface peened at 40° is, however, not as corrosion resistant. The mechanism of corrosion was discussed in the context of corrosion products formed and the opposing influences of initial roughness and compressive residual stresses. While higher roughness promotes hot corrosion by facilitating sites for corrosive attack, higher compressive residual stresses retard the diffusion of corrosive species into the Ti-6Al-4V surface. Based on these discussions, the optimum impact angle for AWJ peening for imparting maximum hot corrosion resistance on Ti-6Al-4V was determined to be ~30°.

Thermal effects and deformation mechanisms in abrasive waterjet machining: insights from Ti-6Al-4V alloy for broader applications

As a novel cold machining method, abrasive waterjet machining (AWJM) has significant potential for processing titanium-based materials such as Ti-6Al-4V alloy. However, the thermal effects and material deformation mechanisms of AWJM remain challenging to explain. This study introduces a six-colour blackbody radiation pyrometry method that successfully monitors transient high temperatures during AWJM. The results revealed that temperatures during AWJM were not negligible, reaching up to 3602.08K, leading to material solidification and oxidation. The flash temperature exhibited transient and continuously oscillating characteristics at the microsecond scale. The combined mechanical and thermal loads created three distinct regions: the jet impact zone (elongated grains, oxide-based compositions, and material melting), the heat-affected zone (larger grains), and the base material zone. In the jet impact zone, a pronounced temperature gradient formed on the surface, promoting grain refinement. However, as the distance from the impact zone increases, the extent of grain refinement diminishes, leading to larger grain sizes. The higher kernel average misorientation values observed in and near the impact zone indicated that high-temperature conditions were insufficient for complete recrystallisation, either because of inadequate diffusion or the short duration of the elevated temperatures. This study reveals the thermal and material deformation mechanisms involved in the AWJM process. This establishes a foundational understanding of the processing of titanium-based and other heat-sensitive materials, ultimately contributing to enhanced overall material performance.

Evaluation of Peripheral Milling and Abrasive Water Jet Cutting in CFRP Manufacturing: Analysis of Defects and Surface Quality

Evaluation of Peripheral Milling and Abrasive Water Jet Cutting in CFRP Manufacturing: Analysis of Defects and Surface Quality

Optimising abrasive water jet cutting parameters for direct metal laser sintered Inconel 718: a study of cutting efficiency and surface quality

Optimising abrasive water jet cutting parameters for direct metal laser sintered Inconel 718: a study of cutting efficiency and surface quality

Exploring surface integrity: Experimental investigation into abrasive waterjet deep hole drilling on ss 316L for biomedical applications

Precision drilling of difficult-to-cut materials with exceptional surface integrity is a crucial factor in producing advanced manufactured components in industries like aviation, automotive, defense, electronic, and medical devices. More specifically, deep hole drilling enables precise customization of prostheses, improving patient comfort and functionality. Abrasive waterjet deep hole drilling has become a vital drilling technique in many industries due to its adaptability and effectiveness in drilling intricate shapes on hard-to-cut materials. The interplay between process parameters and surface finish underscores the need for systematic investigation to enhance drilling efficiency and quality. In this research, an attempt has been made to explore the influence of abrasive waterjet deep hole process parameters viz water pressure and standoff distance on the surface integrity of the drilled holes for biomedical applications. A surface roughness tester has been used to evaluate surface roughness at three distinctive places, namely the top, middle, and bottom of the drilled holes. The investigation showed that surface roughness at the top of the holes is less as compared to the middle and bottom of the holes. The average surface roughness along the depth of the drilled holes is greatly influenced by water pressure. Additionally, the morphology of the drilled holes has been studied using a scanning electron microscope (SEM). SEM images revealed that the top surface of the drilled holes is free from defects.