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Analytical modeling of effective depth of cut for ductile materials via abrasive waterjet machining

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Abstract

Abrasive waterjet (AWJ) cutting technology is widely used for nonconventional cold machining of ductile or brittle materials in various manufacturing fields. However, this technology has a significant limitation in terms of the effective depth of cut. As a solution, in this study, a model for the effective depth of cut is proposed based on the Gaussian distribution of the cut profile curve. The proposed model is used to investigate the dynamic evolution of the depth of cut and its influence mechanism. First, a prediction model for the effective depth of cut is established using the material removal mechanism and single particle erosion theory. In addition, an experimental analysis is conducted to improve and optimize the cutting performance of the AWJ considering the effect of machining parameters on (i) the effective depth of cut and (ii) cutting performance. The key factors that affect the geometric profile characteristics of the kerf are investigated, and the optimal parameters for achieving the effective depth of cut model are further determined. According to the AWJ cutting performance experiments conducted by using Ti-6Al-4 V, the prediction model is strongly correlated with the experimental data, and the average difference between the prediction model and experimental results is 6.46% of the effective depth of cut. Notably, this model can predict the effective depth of a cut for different cutting parameters. Furthermore, it exhibits significant industrial value by expanding the application fields of finishing machining using AWJ technology.

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Acknowledgements

We would like to thank Editage (www.editage.cn) for English language editing.

Funding

This research has been supported by the NSFC-Liaoning Joint Fund (U1708256, U1908232), Fundamental Research Funds for the Central Universities (DUT18GF104), and Joint Fund of MOE and GAD (6141A02022133).

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Authors and Affiliations

  1. School of Mechanical Engineering, Dalian University of Technology, Dalian, 116024, China

    Jianfeng Chen, Yemin Yuan, Hang Gao & Tianyi Zhou

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  1. Jianfeng Chen
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Jianfeng Chen conceived of this study, designed the method, and wrote the manuscript. All authors were involved in collecting and analyzing the data, also revisions.

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Correspondence to Hang Gao.

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Chen, J., Yuan, Y., Gao, H. et al. Analytical modeling of effective depth of cut for ductile materials via abrasive waterjet machining. Int J Adv Manuf Technol 124, 1813–1826 (2023). https://doi.org/10.1007/s00170-022-10538-z

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