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Avoiding carbon fibre reinforced polymer delamination during abrasive water jet piercing: a new piercing method

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Abstract

This paper presents a new method of piercing the carbon fibre reinforced polymer (CFRP) with abrasive water jet (AWJ), which can avoid delamination. The method consists of adding the abrasive particles in the water jet at the very beginning of jet formation, thus obtaining a mixed abrasive water jet during the first impact with the composite work piece. A new cutting system was designed and set up based on the proposed piercing method and was compared with a conventional AWJ cutting system. The main added values brought by this paper are: it validates our original concept; provides synthetic analyses, the effects of the AWJ homogeneity, and the abrasive inlet angle on the CFRP delamination, and it brings a complete set of recommendations on how to overcome the industrial difficulties caused by the delamination of the composite materials, during the piercing with AWJ.

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Abbreviations

Dext :

Delamination extent [mm]

Dmax :

The maximum diameter of delamination [mm]

Dnom :

The nominal hole diameter [mm]

do :

Water orifice diameter [mm]

df :

Focusing tube diameter [mm]

lf :

Focusing tube length [mm]

ma :

Abrasives mass flow [kg/min]

P:

Water pressure [MPa]

Ra :

Surface roughness [µm]

rk :

The top edge radius [mm]

t:

Material thickness [mm]

SOD:

Stand-off distance [mm]

Ψ:

Abrasive inlet angle [degree]

AE:

Acoustic emission

AWJ:

Abrasive water jet

CCD:

Central composite design

CFRP:

Carbon fibre reinforced polymer/plastic

DoE:

Design of experiments

IDZ:

Initial damage zone

UHP:

Ultra high-pressure pump

RSM:

Response Surface Methodology

RCZ:

Rough cutting zone

SCZ:

Smooth cutting zone

WJ:

Water jet

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Funding

This research was supported by HORIZON 2020 – DiCoMI Project, “Directional Composites through Manufacturing Innovation”, GA Nr. 778068.

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Authors and Affiliations

  1. Dept. of Manufacturing Engineering, Technical University of Cluj-Napoca, B-Dul. Muncii, No. 103-105, Cluj-Napoca, Romania

    Ioan Alexandru Popan, Ioan Alexandru Popan, Nicolae Balc & Alina Ioana Popan

Authors
  1. Ioan Alexandru Popan
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  2. Nicolae Balc
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  3. Alina Ioana Popan
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Contributions

All authors contributed to design the proposed method. I.A.P and A.I.P. carried out the experiments. A.I.P. performed the measurements and optical analysis. All authors analysed the experimental results and wrote of the manuscript.

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Correspondence to Ioan Alexandru Popan.

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The authors declare no competing interests.

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Popan, I.A., Balc, N. & Popan, A.I. Avoiding carbon fibre reinforced polymer delamination during abrasive water jet piercing: a new piercing method. Int J Adv Manuf Technol 119, 1139–1152 (2022). https://doi.org/10.1007/s00170-021-08294-7

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  • DOI: https://doi.org/10.1007/s00170-021-08294-7

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