Search Results (57)

Abrasive waterjet machining (AWJM) is widely used for cutting aerospace aluminum alloys, but exit-side defects associated with jet lag can degrade surface integrity and dimensional accuracy. This work investigates the influence of water pressure, abrasive mass flow rate, and traverse feed rate on the formation of jet-lag defects at the exit side of cuts in UNS A92024 aluminum alloy plates of 10 mm thickness. A full factorial 3³ experimental design was implemented to manufacture 27 square samples (20 × 20 mm), which were subsequently characterized by optical microscopy at 20× magnification. The semicircular jet-lag defects were quantified using Imaging processing techniques to determine their projected area, and the resulting data were analyzed with multifactor ANOVA and multiple linear regression. The results show that traverse feed rate and water pressure have a statistically significant effect on defect area, with traverse feed rate being the most influential factor, whereas the abrasive mass flow rate plays a secondary role within the investigated range. Combinations of high water pressure and low traverse feed rate led to cleaner cuts with reduced exit-side damage, and contour plots allowed the identification of operational windows that minimize defect formation. The proposed methodology provides a systematic framework for characterizing jet-lag defects in AWJM and can be extended to other alloys, thicknesses, and advanced characterization techniques to support process optimization in industrial applications. Full article

In this study, Delrin^® (POM) polymer was reinforced with 15 wt.% chopped ramie fiber (RF) to develop a sustainable composite, which was injection-molded and machined using abrasive waterjet machining (AWJM). SEM revealed a skin-core morphology with flow-induced RF alignment and small voids at bundle crossovers, indicating interfacial adhesion. A Taguchi L₉ (3³) design evaluated waterjet pressure (WJP: 100–300 MPa), traverse speed (TS: 100–200 mm/min), and stand-off distance (SoD: 1–3 mm) on kerf width (KW) and surface roughness (SR). Increasing WJP from 100 to 300 MPa lowered mean SR from 6.23 to 4.80 µm (23% reduction) and KW from 1.31 to 1.07 mm (reduction of 18%); enlarging SoD from 1 to 3 mm raised SR from 4.98 to 5.55 µm (an 11% increase) and KW from 1.12 to 1.20 mm (a of 7% increase); and raising TS from 100 to 200 mm/min narrowed KW from 1.24 to 1.11 mm (a 10.5% reduction) with a modest SR decrease from 5.45 to 5.28 µm. ANOVA confirmed WJP as the dominant factor for SR (79.8%), as well as a significant SoD (18.3%). For KW, the influence of WJP (68.8%) was substantial, followed by TS (19.9%) and SoD (11%). Linear models captured the trends well (SR: R² = 88.29%; KW: R² = 93.36%). A desirability-based multi-response optimizer yielded ideal conditions for TS (200 mm/min), WJP (300 MPa), and SoD (1 mm), predicting a KW of 0.94 mm and an SR of 4.1567 µm. Confirmation tests produced a KW (0.970 ± 0.01 mm) and SR (4.27 ± 0.05 µm), which are within 3.19% and 2.73% of the predicted values, validating the DoE regression approach. Full article

Additively manufactured stainless steels are gaining considerable attention in the production of complex components, especially in the aerospace, food production, energy, and biomedical industries. Machining and achieving the desired surface properties of such materials remains a challenge. Abrasive waterjet machining technology appears to be one of the options due to the advantages it brings. Removing support structures and separating individual parts is also one of the possible applications of this technology. This study investigates the effects of process parameters for individual cut qualities (Q1–Q5) of abrasive waterjet on the surface properties of additively manufactured stainless steel (SS 316L) specimens, considering the different mechanical properties of the material due to the direction of layering of the material during its production. Experimental specimens were prepared by selective laser melting technology with parameters ensuring the best possible quality of the resulting part. The results of the study showed changes in the topography of the machined surface, especially in the roughness parameters. Scanning Electron Microscopy and Energy Dispersive X-ray Spectroscopy analysis proved the presence of fragmented abrasive particles in the cut areas. Full article

Due to recent developments across the aerospace, power generation and defense sectors, the demand for flat-surfaced components with extremely high surface quality is rapidly increasing. In this regard, although abrasive machining processes often produce fine, contaminated swarf that is frequently relegated to landfill, these processes remain critical for the engineering sector. Motivated by increasing sustainability and circularity pressures, this narrative review examines the current state of the art in recycling and repurposing the chips, tooling and cutting fluids that are typically generated or consumed within grinding processes. In doing so, a number of methodologies for extracting useful materials from swarf slurries are identified, including pyrometallurgical routes (applied successfully to Ni–Co alloys, for example), hydrometallurgical strategies (e.g., iron leaching from ferrous swarf) and, in the case of non-metallic materials such as CMCs and CFRPs, chemical processing methods. Various means of separating abrasive constituents and removing contaminants from grinding swarf are also highlighted, within which centrifugation and heat treatment are found to be particularly useful for non-ferrous materials such as titanium alloys or composites, whilst ferrous materials are largely magnetically separated. Prospective applications for spent abrasive tooling are also explored, including reuse as shot, waterjet machining feedstock, road surface additives, or mortar in the context of cement production. Likewise, heat- and radiation-based strategies for prolonging cutting-fluid life are highlighted, and their associated sustainability benefits and limitations discussed, despite ultimate disposal still being relegated to fuel usage or landfill. Ultimately, this review identifies the scarcity of grinding-specific recycling process data and highlights the need for robust, publicly accessible recycling strategies for novel material systems. Full article

This research proposes an intelligent modeling and optimization strategy for abrasive waterjet machining (AWJM) of magnesium-based fiber metal laminates (FMLs) reinforced with reduced graphene oxide (r-GO). Experiments were designed using the Box–Behnken method, considering waterjet pressure, stand-off distance, traverse speed, and r-GO content as inputs, while kerf taper (Kt), surface roughness (Ra), and material removal rate (MRR) were evaluated as outputs. Adaptive Neuro-Fuzzy Inference System (ANFIS) models were developed for each response, with their critical optimized hyperparameters such as cluster radius, quash factor, and training data split through the dragonfly optimization (DFO) algorithm. The optimized ANFIS networks yielded a high predictive accuracy, with low RMSE and MAPE values and close agreement between predicted and measured results. Four metaheuristic algorithms including particle swarm optimization (PSO), salp swarm optimization (SSO), whale optimization algorithm (WOA), and the antlion optimizer (ALO) were applied for simultaneous optimization, using a TOPSIS-based single-objective formulation. ALO outperformed the others, identifying 325 MPa waterjet pressure, 2.5 mm stand-off, 800 mm/min traverse speed, and 0.00602 wt% r-GO addition in FMLs as optimal conditions. These settings produced a kerf taper of 2.595°, surface roughness of 8.9897 µm, and material removal rate of 138.13 g/min. The proposed ANFIS-ALO framework demonstrates strong potential for achieving precision and productivity in AWJM of hybrid laminates. Full article

The natural fiber-reinforced nanomaterial filler polymer matrix hybrid composite has superior applications in industrial and manufacturing fields due to its enhanced mechanical and machinability characteristics. However, in order to generate high-quality components, unconventional machining techniques, notably abrasive waterjet machining, have become more popular due to the inhomogeneity of composites, fiber pullout, greater surface roughness, and dimensional inaccuracy under traditional machining. Delamination typically refers to the separation that occurs along a plane parallel to the surface, such as the detachment of a coating from its underlying material or the separation between different layers within the coating itself. This paper investigates the AWJM characteristics of Hibiscus Rosa-Sinensis/Carbon nanotube/Epoxy (HRSCE)-based hybrid composite, focusing on delamination factors at entry, exit, and machining time. An L₂₇ orthogonal array was employed to optimize process parameters, revealing that DF-entry decreased with increasing CNT (wt.%), achieving its lowest values at 3 (wt.%) CNT and 2 mm stand-off distance due to enhanced composite toughness and precise jet focus. Conversely, DF-exit increased with higher CNT (wt.%), stand-off distance and traverse speed, attributed to the composite’s increased brittleness and reduced cutting efficiency. Machining time was predominantly influenced by CNT (wt.%) (92.4%), increasing with higher reinforcement levels due to enhanced material resistance. Response surface methodology models demonstrated high accuracy in predicting machining outcomes, with errors below 3%. Contour and surface plots identified optimal conditions for minimal delamination and machining time as 3 (wt.%) CNT, low stand-off distance (2 mm), and moderate traverse speed (200 mm/min). The SEM and optimal microscopy analysis confirmed that CNT reinforcement positively influenced fiber matrix interfacial integrity and reduced surface damage. Full article

Twinning-induced plasticity (TWIP) steels represent a significant development in automotive steel production, characterized by advanced strength and ductility properties. The present study empirically investigated the effects of process parameters on the cutting process and surface quality of TWIP980 steel sheet by abrasive water jet (AWJ) cutting. The cutting experiments were conducted on 1.4 mm thick sheet metal using four different traverse speeds (50, 100, 200, and 400 mm/min) and four different water jet pressures (1500, 2000, 2500, and 3000 bar). Two different abrasive flow rates (300 and 600 g/min) were also utilized. The cut surfaces were characterized in three dimensions with an optical profilometer. The parameters of surface roughness, kerf width, taper angle, and material removal rate (MRR) were determined. Furthermore, microhardness measurements were conducted on the cut surfaces. The optimal surface quality and geometrical accuracy were achieved by applying a combination of parameters, including 3000 bar of pressure, a traverse rate of 400 mm/min, and an abrasive flow rate of 600 g/min. Concurrently, an effective cutting performance with increased MRR and reduced taper angles was achieved under these conditions. The observed increase in microhardness with increasing pressure is attributable to a hardening effect resulting from local plastic deformation. Full article

Abrasive waterjet technology is a promising sustainable and green technology for cutting underground structures. Abrasive waterjet usage in demolition promotes sustainable and green construction practices by reduction of noise, dust, secondary waste, and disturbances to the surrounding infrastructure. In this study, a numerical framework based on a coupled Smoothed Particle Hydrodynamics (SPH)–Finite Element Method (FEM) algorithm incorporating the Riedel–Hiermaier–Thoma (RHT) constitutive model is proposed to investigate the damage mechanism of concrete subjected to abrasive waterjet. Numerical simulation results show a stratified damage observation in the concrete, consisting of a crushing zone (plastic damage), crack formation zone (plastic and brittle damage), and crack propagation zone (brittle damage). Furthermore, concrete undergoes plastic failure when the shear stress on an element exceeds 5 MPa. Brittle failure due to tensile stress occurs only when both the maximum principal stress (σ₁) and the minimum principal stress (σ₃) are greater than zero at the same time. The damage degree ($\chi$) of the concrete is observed to increase with jet diameter, concentration of abrasive particles, and velocity of jet. A series of orthogonal tests are performed to analyze the influence of velocity of jet, concentration of abrasive particles, and jet diameter on the damage degree and impact depth (h). The parametric numerical studies indicates that jet diameter has the most significant influence on damage degree, followed by abrasive concentration and jet velocity, respectively, whereas the primary determinant of impact depth is the abrasive concentration followed by jet velocity and jet diameter. Based on the parametric analysis, two optimized abrasive waterjet configurations are proposed: one tailored for rock fragmentation in tunnel boring machine (TBM) operations; and another for cutting reinforced concrete piles in shield tunneling applications. These configurations aim to enhance the efficiency and sustainability of excavation and tunneling processes through improved material removal performance and reduced mechanical wear. Full article

The use of UHP for food processing includes many applications such as cutting, peeling, pasteurization, and pumping through the orifice to affect food rheology. This paper focuses on food cutting applications using UHP waterjets. State-of-the-art food cutting systems are described including pumps, manipulators, sensors, cutting heads, and software. While UHP technology is commercially available at 621 MPa of pressure, most food cutting systems’ pressure is below 400 MPa. Highly focused waterjets are important for efficient slicing of food and thus diamond orifices with sharp entry edges are used in specially designed cutting using fast acting on/off valves. Automation is at an advanced level for fish, pin bone removal, poultry, meat, and vegetable processing systems where upstream sensor data are used with CNC controllers to determine the paths of the cutting jet(s) at relatively high production rates for portioning or trimming to tight specifications. Harvesting lettuce proved to be highly successful in improving the overall productivity and working environment ergonomics. An important advantage of the waterjet in increasing the shelf life of trimmed food is presented. For example, celery and lettuce shelf life increases by days over mechanical cutting. The use of salt as an abrasive material in abrasive waterjet cutting nozzles was found to be impractical for cutting meat with bone and more work is needed in this area. Bakery, cake, and sandwich cutting applications are utilized in actual plants in the USA and Europe. For example, small envelop cake cutting machines using relatively low-power jets are used for cutting cake into different shapes. Full article

The use of 3D roughness parameters is increasingly gaining ground in various areas of engineering, especially in academic research. In many cases, however, these studies primarily cover the illustration of the character of the surfaces, the interpretation of areal numerical roughness values is often disputed. The goal of this paper is to examine how the 2D and 3D roughness parameters change in the case of anisotropic surfaces, such as surfaces cut with an abrasive water jet. For this purpose, abrasive water jet cutting experiments were performed on AlMgSi0.5 aluminum alloy using different technological parameters. After the experiments, two amplitude-type 3D roughness parameters (S_a and S_z) of the cut surface and four profile parameters (R_a, R_z for roughness and P_a, P_z for raw profile) were measured at five different depths. Our conducted research indicates that the 3D parameters represent a kind of average value for certain roughness characteristics and a maximum value for others. The paper also reports on how these roughness characteristics change as a function of feed speed. Full article

The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A description of this process and its influencing parameters are first presented in this paper, along with process models for the AWJ tool itself and also for the jet–material interaction. The AWJ material removal process occurs through the high-velocity impact of abrasive particles, whose tips micromachine the material at the microscopic scale, with no thermal or mechanical adverse effects. The macro-characteristics of the cut surface, such as its taper, trailback, and waviness, are discussed, along with methods of improving the geometrical accuracy of the cut parts using these attributes. For example, dynamic angular compensation is used to correct for the taper and undercut in shape cutting. The surface finish is controlled by the cutting speed, hydraulic, and abrasive parameters using software and process models built into the controllers of CNC machines. In addition to shape cutting, edge trimming is presented, with a focus on the carbon fiber composites used in aircraft and automotive structures, where special AWJ tools and manipulators are used. Examples of the precision cutting of microelectronic and solar cell parts are discussed to describe the special techniques that are used, such as machine vision and vacuum-assist, which have been found to be essential to the integrity and accuracy of cut parts. The use of the AWJ machining process was extended to other applications, such as drilling, boring, milling, turning, and surface modification, which are presented in this paper as actual industrial applications. To demonstrate the versatility of the AWJ machining process, the data in this paper were selected to cover a wide range of materials, such as metal, glass, composites, and ceramics, and also a wide range of thicknesses, from 1 mm to 600 mm. The trends of Industry 4.0 and 5.0, AI, and IoT are also presented. Full article

The bevel cutting of large-thickness plates is a key process in modern industries. However, traditional processing method such as air-arc gouging bevel cutting or laser bevel cutting may cause serious deformation and rough surface quality due to the defects of the thermal cutting method. In order to improve the quality and efficiency of bevel processing, the abrasive waterjet cutting method is used in this research to overcome the challenge for bevel machining of high-strength DH40 steel plates with a large thickness. For different kinds of beveled structures, a 3D camera is used to measure the reference points defined on the workpiece and the SVD registration algorithm is adopted to transform the theoretical coordinate system to the actual coordinate system. Furthermore, the distance between the nozzle and the workpiece surface is also measured and compensated for to ensure the consistency of the bevel width. Finally, experiments are carried out for different kinds of bevels to verify the feasibility of the proposed method for high precision processing for beveled structures. The developed method has been effectively applied in the actual shipbuilding industry. Full article

This paper introduces an Acoustic Emission (AE)-based monitoring method designed for supervising the Abrasive Waterjet Cutting (AWJC) process, with a specific focus on the precision cutting of Carbon Fiber-Reinforced Polymer (CFRP). In industries dealing with complex CFRP components, like the aerospace, automotive, or medical sectors, preventing cutting system malfunctions is very important. This proposed monitoring method addresses issues such as reductions or interruptions in the abrasive flow rate, the clogging of the cutting head with abrasive particles, the wear of cutting system components, and drops in the water pressure. Mathematical regression models were developed to predict the root mean square of the AE signal. The signal characteristics are determined, considering key cutting parameters like the water pressure, abrasive mass flow rate, feed rate, and material thickness. Monitoring is conducted at both the cutting head and on the CFRP workpiece. The efficacy of the proposed monitoring method was validated through experimental tests, confirming its utility in maintaining precision and operational integrity in AWJC processes applied to CFRP materials. Integrating the proposed monitoring technique within the framework of digitalization and Industry 4.0/5.0 establishes the basis for advanced technologies such as Sensor Integration, Data Analytics and AI, Digital Twin Technology, Cloud and Edge Computing, MES and ERP Integration, and Human-Machine Interface. This integration enhances operational efficiency, quality control, and predictive maintenance in the AWJC process. Full article

Improvement of the surface quality of machined parts is essential in order to avoid excessive and costly post-processing. Although non-conventional processes can efficiently carry out the machining of difficult-to-cut materials with high productivity, they may also, for various reasons, be related to increased surface roughness. In order to optimize the surface quality of generated surfaces in a reliable way, surface profiles obtained during these processes must be adequately modeled. However, given that most studies have focused on Ra or Rz indicators or are based on the assumption of a normal distribution for the profile heights, relevant models cannot accurately represent the surface characteristics that exist in a real machined surface with a high degree of accuracy. Thus, in the present study, a new modeling approach based on the use of a statistical probability distribution for the surface profile height is proposed. After six different distributions were evaluated on the basis of a three-stage procedure involving different roughness indicators pertaining to the abrasive waterjet (AWJ) milling of pockets, it was found that, although it is not possible to model the nominal values of every roughness parameter simultaneously, in several cases, it is possible to approximate the values of critical indicators such as Ra, Rz, Rsk, Rku and Rp/Rv ratio by Weibull distribution with a sufficient degree of accuracy. Full article

Abrasive waterjet (AWJ) machining offers the possibility of creating a wide range of features on mechanical parts with different degrees of complexity with a relatively high efficiency. However, after the roughing passes, the surface quality of features such as blind pockets is rather low, with unfavorable implications for surface waviness and form deviations apart from high surface roughness. Apart from the traditional methods for finishing, such as grinding or lapping, it is worth attempting either to improve the surface quality obtained during roughing by an AWJ or to integrate a post-processing step by using a pure WJ in the existing process in order to ameliorate the surface quality. Thus, in the current study, the effect of pure waterjet (WJ) post-processing of machined pockets by AWJ milling on a Ti-6Al-4V workpiece using recycled glass beads was investigated under different conditions. The findings indicate that although the different post-processing treatments by a pure WJ can affect the surface quality on average, these differences are not considerably important, probably due to an insufficient capability of material removal, which hinders the smoothing effect on machined surfaces. Thus, it was indicated that a higher number of post-processing passes under different conditions than those of the roughing pass can be more favorable for efficient post-treatment by a pure WJ. Full article