Abrasive Waterjet Machining of Engineering Materials: (Volume 19 Materials Science Foundations)

Manufacturing industry is becoming ever more time-conscious with regard to the global economy, and the need for rapid prototyping and small production batches is increasing. These trends have placed a premium on the use of new and advanced technologies for quickly turning raw materials into usable goods; with no time being required for tooling. The need for advanced processing technologies is particularly evident when machining advanced materials, such as ceramics, composites and thermo-sensitive materials that have wide application but are considered to be "difficult-to-machine" using conventional machining technologies such as turning and milling. Abrasive waterjet (AWJ) machining has been found to be one of the advanced technologies that meet these processing requirements due to its distinct advantages over other machining technologies. The emphasis of this book is placed squarely on the practical application of AWJ machining technology, and covers all necessary details of the fundamental scientific aspects. It provides a detailed analysis of the effects of the main processing parameters upon cutting performance when machining typical engineering materials, as well as detailing novel techniques for enhancing the cutting performance. Following a brief introductory chapter, the fundamentals of the AWJ machining process are reviewed, including material erosion mechanisms and predictive machining-performance models. Jet dynamic characteristics, based upon a simulation study, are then described. These form a fundamental basis for understanding the contents of the remainder of the book. This is followed by chapters, on the cutting of representative engineering materials, with regard to both straight-slit cutting and contouring. A critical analysis of the mechanisms of surface striation formation is then presented, as well as the various factors which result in surface striation during AWJ machining. The book concludes with valuable tips concerning the various techniques that can effectively enhance the cutting performance of AWJ machining. This book should be useful to both researchers and postgraduates or final-year undergraduates who are specializing in manufacturing processes. It should also be particularly useful to those industrial users of materials processing who are charged with making AWJ machining more efficient.

Table of Contents:
Preface Nomenclature 1. Introduction. 1.1 Abrasive Waterjet Systems 1.2 Characteristics 1.3 Applications 2. Fundamentals of AWJ Machining. 2.1 Material Removal Mechanisms 2.2 Kerf Characteristics 2.3 Mathematical Models for Cutting Performance 3.Characteristics of Abrasive Waterjet. 3.1 CFD Model Formulation 3.2 Results and Discussion 4. AWJ Cutting of Typical Engineering Materials. 4.1 AWJ Cutting of Metallic Coated Sheet Steels 4.2 AWJ Cutting of Industrial Ceramics 4.3 AWJ Cutting of Polymer Matrix Composites 5. AWJ Contouring. 5.1 Experiment 5.2 Analysis of Kerf Characteristics 6. The Formation Mechanisms of Surface Striations 6.1 Striation Formation Due to the Characteristics Inherent to the Cutting Process. 6.2 Striation Formation Due to Jet Dynamic Characteristics and Energy Dissipation 6.3 Striation Formation due to System Vibration 6.4 Concluding Remarks 7.Techniques for Enhancing the Cutting Performance. 7.1 Forward Angling the Jet 7.2 Controlled Nozzle Oscillation 7.3 Multipass Cutting Operations 7.4 Concluding Remarks References