Modelling and simulation of controlled depth abrasive water jet machining (AWJM) for roughing passes of free-form surfaces

Controlled depth abrasive waterjet machining (AWJM) is an unconventional and promising process for materials introducing challenges in conventional high value manufacturing (HVM) industries such as aerospace automotive. In applications, acts a flexible cutting tool compared to milling. The kerf profile, i.e. the removed material volume, nonlinearly depends on parameters water pressure, jet traverse speed, rate, stand-off-distance unlike deterministic case mechanical Thus, prediction of width, depth, shape, great importance accurate efficient development path generation AWJM. this paper, novel analytical model proposed relying conservation energy momentum, where removal related machinability number workpiece material, so that requirement calibration tests eliminated. Then, AWJM used framework predict 3D in-process (IPW) geometry, which represented using signed distance field (SDF) approach. verified by experimental results with average error 15%, machine profiles are measured confocal optical microscopy. some experiments, undulated was observed due inconsistent supply system, considered be major source errors. IPW simulation variable speed considering significant effect depth. machined specimens sectioned along direction cross section test pieces visually simulations. introduced amount may attributed non-consistent system. It shown approach demonstrates reasonable accuracy plan controlled processes.