Numerical research on kerf characteristics of abrasive waterjet machining based on the SPH-DEM-FEM approach
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ORIGINAL ARTICLE
Numerical research on kerf characteristics of abrasive waterjet machining based on the SPH-DEM-FEM approach Mingming Du 1,2 & Haijin Wang 1,2
&
Huiyue Dong 1,2 & Yingjie Guo 1,2 & Yinglin Ke 1,2
Received: 6 August 2020 / Accepted: 30 October 2020 / Published online: 11 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Abrasive waterjet machining has been widely used because of flexibility, but the cutting accuracy is difficult to ensure due to the lack of dynamic analysis in the forming process of the kerf. In this paper, a coupled SPH-DEM-FEM method is proposed to predict the cutting qualities of the abrasive water jet machining under different process parameters and reveal the mechanism of the kerf formation. Compared with previous simulation methods, the new simulation method has advantages in the simulations for long-term water jet cutting. The abrasive particles and waterjet particles are continuously generated during calculations to reduce the model size and raise the calculation efficiency. The discrete element method (DEM) is utilized to characterize the flow of abrasive particles, which follows the Gaussian distribution. The collisions of non-spherical particles are concerned by the friction factors. The water flow with large deformation is expressed in the smoothed particle hydrodynamics (SPH) method. And the erosion contact is set between particles and the target. Finally, experiments are conducted to verify the authenticity of the simulation model. The cutting depths and kerf top widths obtained by the simulations are consistent with the experimental results. Keywords Abrasive waterjet machining . Cutting characteristics . Numerical simulation . Smoothed particle hydrodynamics (SPH) . Discrete element method (DEM)
1 Introduction As an alternative non-conventional machining process for difficult-to-cut materials, abrasive waterjet (AWJ) machining has received critical attention with the advantages of no thermal distortion, low cutting forces, and high machining versatility [1, 2]. Thus, it has been widely used in various industries, including the mechanical precision component, intelligent automotive engineering, and aerospace equipment, where the machining performance with high accuracy and quality is required [3, 4]. As a critical factor affecting its application, the characteristics of kerf have been particularly concerned [5]. Various research methods, such as experimental analysis [6, 7], theoretical modeling [8, 9], * Haijin Wang [email protected] 1
State Key Laboratory of Fluid Power and Mechatronic Systems, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China
2
Key Laboratory of Advanced Manufacturing Technology of Zhejiang Province, College of Mechanical Engineering, Zhejiang University, Hangzhou 310027, China
and numerical simulation [10, 11], are applied to study the performance of AWJ machining. Nevertheless, the numerical method has attracted increasing attention because of its efficiency and rationality recentl
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