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The International Journal of Advanced Manufacturing Technology (2018) 97:1779–1786

https://doi.org/10.1007/s00170-018-2011-0

ORIGINAL ARTICLE

The optimal cutting times of multipass abrasive water jet cutting


Xiaojin Miao 1 & Zhengrong Qiang 1 & Meiping Wu 1 & Lei Song 1 & Feng Ye 1

Received: 20 December 2017 / Accepted: 4 April 2018 / Published online: 2 May 2018
# Springer-Verlag London Ltd., part of Springer Nature 2018

Abstract
Cutting is one of the most important applications of abrasive water jet. However, there are always some quality defects in the
cross section cut by abrasive water jet. It is found that multipass abrasive water jet cutting can effectively improve the cutting
quality. In this paper, two types of multipass water jet cutting were summarized and redefined clearly first. Then, taking AISI 304
stainless steel as the workpiece, the cross sections after cutting with different cutting times were analyzed and compared with that
after single cutting. The overall roughness and the overall taper of the section were obtained by a reasonable method. Besides, in
order to give consideration to both the cutting quality and the processing time, the concept of quality improvement rate was put
forward. On this basis, with the improvement rate as the index, the optimal cutting times for cutting AISI 304 stainless steel with
multipass abrasive water jet were analyzed from two aspects of surface quality and kerf taper, and the optimal cutting times of
cutting other materials by multipass abrasive water jet can be studied according to the same idea. The study of this paper provides
important reference for the application of multipass abrasive water jet cutting.

Keywords Abrasive water jet . Multipass cutting . Optimal cutting times . Surface quality . Kerf taper

1 Introduction of the work of removing materials is the high-speed particles.


Compared with traditional machining methods such as laser
With the rapid development of technology, products are re- and electric discharge machining (EDM), abrasive water jet is
quired to develop towards high precision, high power, and the only cool procession technique. It has many advantages
miniaturization. The materials used are more and more diffi- such as no heat effect, small reaction force, high flexibility,
cult to process. It is difficult to process these materials with and environmental protection [2–6]. Nevertheless, the cross
high precision and flexibility only by traditional processing section cut by abrasive water jet has unavoidable defects.
technology. High-pressure abrasive water jet is a new process- Therefore, abrasive water jet cutting technology is difficult
ing technology developed on the basis of pure water jet at the to extend from the field of rough machining and semi fine
beginning of the 1980s [1]. It is a liquid-solid two-phase jet machining to the field of fine machining. The further devel-
formed by a mixture of abrasive and high-pressure water. opment of the technology is greatly limited [7, 8].
Abrasive particles are accelerated by high-pressure water after The most important application of abrasive waterjet
the mixture of the abrasive particles and the high-pressure technology is cutting. However, there are some defects in
water. Then, the accelerated particles are ejected from the the cross section cut by abrasive water jet, such as stria-
nozzle together with the high-pressure water. The high-speed tions, kerf taper, and cutting residue. Among these defects,
jet ejected from the nozzle is the so-called abrasive water jet. striations and kerf taper have the most serious effects on
High-speed particles have strong energy. The main undertaker the cutting quality. In order to improve the cutting quality
of abrasive water jet so that accelerate the transition course
of abrasive water jet from the field of rough machining and
* Xiaojin Miao semi fine machining to the field of fine machining, many
miaoxiaojin126@126.com experts have done a lot of researches.
Generally, the cross section cut by abrasive water jet can be
1
Key Laboratory of Advanced Food Manufacturing Equipment &
divided into several zones according to the quality of the sur-
Technology, School of Mechanical Engineering, Jiangnan face, mainly including initial zone, smooth zone, and rough
University, Wuxi 214122, China zone [9–12]. The range of the initial zone is very small. The

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1780 Int J Adv Manuf Technol (2018) 97:1779–1786

initial zone is mainly formed by the initial contact of the jet processing time and cutting quality, the optimal cutting times
and the workpiece. It exists at the top end of the cross section of multipass abrasive water jet were explored. With the opti-
[11]. The energy of the jet decreases in the direction of depth, mal cutting times, the quality of the section can be improved
so the ability of the jet to remove the material at the lower part most efficiently.
of the workpiece is insufficient. Thus, the striations are
formed. Whether the striations exist or not is an important
reference for the division of the smooth zone and the rough
2 Experimental design
zone. Among these zones, the surface quality of the smooth
zone is the best, while the surface quality of the rough zone is
2.1 Operation forms
the worst due to the existence of striations. Therefore, in order
to achieve the purpose of improving the surface quality of the
There are two types of multipass abrasive water jet cutting.
section, the striations must be eliminated as many as possible.
The first type is shown in Fig. 1. The workpiece is cut off after
Chen [13] and Lemma [14] found that the cutting depth is the
the first cutting, and the subsequent cutting can be considered
largest when the incident angle is 80–85°. Therefore, they
to be “trimming” to a greater extent. Therefore, this type can
proposed and adopted the cutting method of nozzle oscillation
be called “multipass trimming-cutting”. The second type is
to improve the range of the smooth zone. With the expansion
shown in Fig. 2. The workpiece is cut off after the multipass
of the range of the smooth zone, the overall quality of the
cutting is completed, that is, the cutting of the workpiece is
surface is improved. The range of the smooth zone can be
completed by multiple cutting. As shown in Eq. 1, in the ideal
improved by 30% with the method of nozzle oscillation. The
case, the cutting depth of each cutting of this cutting scheme is
optimum oscillation angle is 15–20°, and the best oscillating
the same. The workpiece is just cut off after the cutting is
frequency depends on the cutting speed. Zeng [15] and Hlaváč
completed. Therefore, this type can be referred to as
[16] use the cutting method of nozzle tilt compensation to cut
“multipass deepening-cutting”.
the workpiece. It is found that this cutting method can effec-
tively reduce the striations caused by the deflection of the jet. d
The cutting method of nozzle oscillation and the cutting meth- dD ¼ ð1Þ
N
od of nozzle tilt compensation are the two most widely recog-
nized cutting methods which can effectively eliminate
striations. Where, dD is the cutting depth of each cutting of deepen-
The kerf taper is formed in the process of water jet cutting, ing-cutting, d is the thickness of the workpiece, and N is the
which is influenced by many process parameters. Through the total number of cutting times.
study, Matsui [17] found that the process parameter that has Some experts have studied multipass deepening-cutting,
the greatest influence on the kerf taper is the traverse speed. but have not given the evaluation criteria of the optimal cut-
Besides, Hashish [18] and Wang [19] found that, on the pre- ting times. And in the aspect of multipass trimming-cutting,
mise of the other process parameters remain unchanged, the almost no research paper has been found at present. That is to
shape of the kerf changes from “Λ” to “V” with the increase of say, the multipass abrasive water jet cutting studied by prede-
the traverse speed. Obviously, the kerf taper decreases first cessors mostly refers to the deepening-cutting. In this paper,
and then increases during this change. Therefore, the kerf the generalized induction and redefinition of multipass abra-
taper can be effectively reduced by adjusting the traverse sive water jet cutting is made.
speed. In addition to adjusting the process parameters, the kerf The common point of the two types of multipass cutting is
taper can also be reduced by using the cutting method of to remain other process parameters except the traverse speed
nozzle oscillation. Through the study, Xu [20] found that the unchanged. The difference is that the multipass trimming-
cutting quality would be reduced if the cutting parameters cutting is to keep the traverse speed unchanged after the first
were not selected properly by using the cutting method of cutting. Then, the cutting is repeated many times. This type of
nozzle oscillation. With the best combination of cutting pa- multipass cutting obviously increases a lot of processing time.
rameters, the kerf taper can be reduced by 54%. The processing time increased by multipass trimming-cutting
In addition to the above existing and widely recognized is shown in Eq. 2.
methods that can effectively improve the cutting quality of T tΔ ¼ ðN −1Þ⋅T ð2Þ
abrasive water jet, Hashish [21] and Wang [22] believe that
multipass abrasive water jet cutting can also effectively im- Where, TtΔ is the processing time increased by multipass
prove the cutting quality. But at present, multipass abrasive trimming-cutting, and T is the processing time required for the
water jet cutting has been rarely studied. In this paper, the single cutting.
cutting of AISI 304 stainless steel with multipass abrasive The multipass deepening-cutting is to cut off the workpiece
water jet was taken as an example. By weighing the after multiple cutting. In ideal case, the depth of each cutting is

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Int J Adv Manuf Technol (2018) 97:1779–1786 1781

First cutting Second cutting Third cutting 10

Workpiece AWJ
8

depth of cut (mm)


6

4
Striations Cutting direction
Fig. 1 Multipass trimming-cutting
2

almost the same. That is, the traverse speed of each cutting 0
140 190 240 290 340 390 440
remains unchanged, but it is several times than that of the
Traverse speed (mm/min)
single cutting (Eq. 3).
Fig. 3 The relationship between the cutting depth and the traverse speed
d (standoff distance = 7 mm; abrasive flow rate = 0.6 kg·min−1; pressure =
v2i ¼ ⋅v ð3Þ 280Mpa)
N
Where, v2i is the ideal traverse speed of the multipass deep-
ening-cutting, and v is the traverse speed of the single cutting. Where, TdΔ is the processing time increased by multipass
In theory, multipass deepening-cutting does not increase deepening-cutting, dw is the width of workpiece, vΔd is the
the processing time. But in fact, there is no linear relationship speed compensation of traverse speed to the nonlinear influ-
between the cutting depth and the traverse speed. Figure 3 is ence of cutting depth, and vΔD is the speed compensation for
the relationship between the cutting depth and the traverse actual standoff distance.
speed. It can be seen from the figure that the decline rate of Thus, it can be seen that both the two types of multipass
the cutting depth decreases with the increase of the traverse cutting are to improve the quality of the cutting section by
speed. This means that the traverse speed required for each sacrificing a certain processing efficiency.
cutting is slower than that of the ideal condition.
In addition, as shown in Eq. 4, the actual standoff distance
of the next cutting is one cutting depth longer than the previ- 2.2 Experimental planning
ous one after each cutting. The increase of the standoff dis-
tance leads to the decrease of the cutting capacity of the jet. In The factors that affect the cutting quality of abrasive wa-
order to achieve the desired cutting depth, it is also necessary ter jet mainly include pressure, abrasive flow, standoff
to reduce a certain traverse speed. distance, traverse speed, nozzle diameter, impact angle,
and abrasive property [23, 24]. The purpose of this paper
d is to study the effect of multipass abrasive water jet cut-
Dn ¼ D þ ⋅ðn−1Þ ð4Þ
N ting times on cutting quality. Therefore, according to the
research characteristics of this paper, other process param-
Where, Dn is the actual standoff distance of the nth cutting,
eters except traverse speed must remain unchanged. The
and D is the standoff distance of the first cutting.
specific setting of the process parameters is shown in
Therefore, the processing time increased by multipass
Table 1.
deepening-cutting is as follows:
60⋅n⋅d w Table 1 Experiment conditions
T dΔ ¼ −T ð5Þ
v2i −vΔd −vΔD Parameters Value

Nozzle diameter (mm) 0.7


First cutting Second cutting Third cutting Standoff distance (mm) 7
Traverse speed (mm/min) 140, 240, 320, 400
AWJ
Abrasive flow rate (kg/min) 0.6
Impact angle (°) 90
Pressure (MPa) 280
Abrasive mesh number (#) 100
Workpiece thickness (mm) 10
Workpiece Cutting direction
Workpiece width (mm) 100
Fig. 2 Multipass deepening-cutting

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1782 Int J Adv Manuf Technol (2018) 97:1779–1786

a Third cutting 3 Results and discussion


Second cutting
3.1 Surface quality
First cutting
Figure 5 shows the cross section after abrasive water jet single
Workpiece cutting. The workpiece was just cut off. It can be seen from the
figure that if the traverse speed is high or the cutting power is
small, the range of the smooth zone will be very small. In
addition to the common smooth and rough zones, there is also
a reflection zone below the rough zone of the section. The
Striations
reflection zone has a lot of erosion pits, and the surface quality
of this zone is the worst. Besides, there is a large triangular
b Third cutting cutting residue at the cutting exit. In general, there are many
Second cutting defects in the cross section. The surface quality of the cross
section is bad.
First cutting
Figure 6 shows the cross section after multipass trimming-
cutting. It can be seen from the figure that the range of the
Workpiece smooth zone expands with the increase of the number of cut-
ting. Compared with the single cutting, the surface quality of
the section after two times trimming-cutting was greatly im-
proved. The range of the smooth zone is more than half of the
Striations section, and the sizes of the striations were reduced a lot. Only
a few of the erosion pits were left, and the scopes of the
Fig. 4 Multipass cutting direction. a Single direction. b Alternate
direction erosion pits are small. Even so, the rough zone on the cross
section is still large, and the striations are obvious. There is
also a small scope of triangular cutting residue on the cross
section. Compared with the section after two times trimming-
In addition, as shown in Fig. 4, the multipass cutting cutting, the surface quality of the section after three times
direction can be single or alternate. In single direction trimming-cutting was greatly improved. The range of the
cutting, after every passage, the nozzle needs to return rough zone was further reduced, and the striations were re-
to the origin, which will waste a certain time and affect duced a lot. There is little cutting residue at the cutting exit.
the experimental results. Therefore, this paper adopts al- Compared with the section after three times trimming-cutting,
ternate direction cutting. the surface quality of the section after four times trimming-
As shown in Table 2, in order to facilitate a better cutting was further improved. The striations are almost no
understanding of the experimental scheme, the overall ex- longer existed. The smooth zone almost occupies the whole
perimental layout is presented in the form of a table. section.
In this paper, the AISI 304 stainless steel was used as Figure 7 shows the cross section after multipass deepening-
the workpiece, and other materials refer to the same re- cutting. As can be seen from the figure, the stratification of the
search idea. section after two times deepening-cutting is obvious. The

Table 2 Experimental layout


Cutting scheme Total The cutting times Traverse speed (mm/ Cutting
cutting when the workpiece is cut min) direction
times off

Single cutting 1 1 140 /


Trimming-cutting 2 1 140 Alternate
3 1 140 Alternate
4 1 140 Alternate
Deepening-cutting 2 2 240 Alternate
3 3 320 Alternate
4 4 400 Alternate

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Int J Adv Manuf Technol (2018) 97:1779–1786 1783

Striations Smooth zone Rough zone

(a) Two times deepening-cutting

Erosion pit Reflection zone Cutting residue


Fig. 5 Cross section after single cutting
(b) Three times deepening-cutting

surface quality of the upper layer is good, while, the surface


quality of the lower layer is quite bad. The erosion pits in the
lower layer are not only large but also deep, and the striations (c) Four times deepening-cutting
of it are obvious. In addition, there is still a certain cutting Fig. 7 Cross section after deepening-cutting. a Two times deepening-
residue at the cutting exit. The stratification of the section after cutting. b Three times deepening-cutting. c Four times deepening-cutting
three times deepening-cutting is also obvious, and the surface
quality of the three layers decreases gradually from top to By measurement and calculation, the overall roughness of
bottom. There is a lot of erosion pits at the bottom layer, but each cutting scheme is as follows:
compared with the erosion pits on the section after two times As can be seen from Table 3, each time the cutting times of
deepening-cutting, the sizes and depths of the erosion pits are multipass trimming-cutting and deepening-cutting is in-
smaller. After four scours, the first and second layers of the creased, the surface quality of the cross section has a certain
upper part of the section are almost integrated into one, and the increase, but the extent of improvement is decreasing. In ad-
surface quality of the part is better. Erosion pits also exist in dition, under the same cutting times, the improvement of the
the lower part of the section, but the sizes and depths of the cutting quality by multipass trimming-cutting is better than
erosion pits are much smaller than that of the erosion pits on that by multipass deepening-cutting.
the section after three times deepening-cutting.
As shown in Eq. 6, in order to further analyze the improve-
ment of the surface quality of various cutting schemes, the 3.2 Kerf taper
roughness of each zone of each cross section is measured
respectively. The average value of the roughness obtained by With the exception of surface quality, kerf taper is also an
multiple measurements is taken as the average roughness of important index to judge the quality of the cutting section of
the zone. Then, the average roughness of each zone is multi- abrasive water jet.
plied by the proportion of the zone, and the sum of the prod- Figure 8 shows the side of the cross section after single
ucts is taken as the overall roughness of the cross section. cutting. It can be seen that the kerf taper and the size of the
  cutting residue after single cutting are very large. Figure 9
x di
Ra ¼ ∑ Rai ⋅ ð6Þ shows the side of the cross section after trimming-cutting. It
i¼1 d can be seen from the figure that trimming-cutting can effec-
tively improve the taper of the kerf. With the increase of cut-
Where, Ra is the overall roughness of the section, Rai is the
ting times, the taper is getting smaller and smaller. Figure 10
average roughness of each zone, di is the depth of a certain
shows the side of the cross section after deepening-cutting. It
zone on the section, x is the number of the zones on the
can be found from the figure that the taper after deepening-
section.
cutting is not a constant. It was segmented into several parts
corresponding to different layers. In general, with the increase
of the number of cutting, the taper is also getting smaller and
smaller.

(a) Two times trimming-cutting Table 3 Roughness of


cross section after cutting Scheme Ra/μm
with different schemes
Single cutting 11.95
(b) Three times trimming-cutting
Two times trimming-cutting 3.59
Three times trimming-cutting 2.89
Four times trimming-cutting 2.85
Two times deepening-cutting 9.80
(c) Four times trimming-cutting Three times deepening-cutting 9.26
Fig. 6 Cross section after trimming-cutting. a Two times trimming- Four times deepening-cutting 9.05
cutting. b Three times trimming-cutting. c Four times trimming-cutting

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1784 Int J Adv Manuf Technol (2018) 97:1779–1786

(a) Two times (b) Three times

Fig. 8 Kerf taper after single cutting

Likewise, in order to further analyze the improvement of


the kerf taper of various cutting schemes, the kerf taper of each
cross section is measured. In order to reduce the measurement
error, the kerf taper of each section is measured three times, (c) Four times
and the average value is regarded as the kerf taper of the Fig. 10 Kerf taper after deepening-cutting. a Two times. b Three times. c
section. For the multistage cone angle, the overall kerf taper Four times
is calculated by referring to the idea of calculating the overall
roughness. The results after measurement and calculation are cutting. That is to say, without considering the processing effi-
shown in Table 4. ciency, trimming-cutting is better than deepening-cutting if the
As can be seen from Table 4, both trimming-cutting and quality improvement effect is considered as the main index. In
deepening-cutting can effectively improve the kerf taper. With this case, the more the number of cutting times are, the better
the increase of the cutting times, the kerf taper gradually de- surface quality can be obtained. Therefore, trimming-cutting is
creases, and it is reduced to a lower level after three times a good choice in the presence of high cutting quality require-
cutting. ments. However, if the requirement for cutting quality is not
very strict, it is impossible for enterprises to improve the cutting
3.3 Optimal cutting times quality by sacrificing processing efficiency without limitation.
Therefore, the cutting quality and processing efficiency must be
Through the preceding analysis, it can be found that after the weighed.
same cutting times, the surface quality of the cross section after As mentioned before, both trimming-cutting and
trimming-cutting is much better than that after deepening- deepening-cutting can effectively improve the surface quality
and the kerf taper. With the increase of cutting times, the
cutting quality is gradually improved. However, the improve-
ments of cutting quality are at the cost of adding some pro-
cessing time. That is to say, it is unreasonable to improve the
cutting quality by increasing cutting times blindly. This will
waste a lot of time. Therefore, it is necessary to choose the
optimal cutting times by weighing the processing time and
cutting quality (Table 5). Only in this way can the best cutting

(a) Two times (b) Three times


Table 4 Kerf taper of cross section after cutting with different schemes

Scheme Kerf taper

Single cutting 6.18°


Two times trimming-cutting 4.16°
Three times trimming-cutting 0.76°
Four times trimming-cutting 0.48°
Two times deepening-cutting 5.62°
(c) Four times Three times deepening-cutting 1.99°
Fig. 9 Kerf taper after trimming-cutting. a Two times. b Three times. c Four times deepening-cutting 1.18°
Four times

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Int J Adv Manuf Technol (2018) 97:1779–1786 1785

Table 5 Cutting time of different schemes K 1 −K n


I Kn ¼ ð8Þ
T n −T
Scheme Cutting time/s
Where, IRn is the surface quality improvement rate of nth
Single cutting 42.86
cutting, Tn is the time needed for n times cutting, Rn is the
Two times trimming-cutting 85.72
surface roughness after nth cutting, R1 is the surface roughness
Three times trimming-cutting 128.58
after single cutting, IKn is the taper improvement rate of nth
Four times trimming-cutting 171.44
cutting, Kn is the kerf taper after nth cutting, and K1 is the kerf
Two times deepening-cutting 50
taper after single cutting.
Three times deepening-cutting 56.25
The experimental data are brought into Eqs. 7 and 8, and
Four times deepening-cutting 60 the line charts are drawn according to the results.
Obviously, the number of cutting times corresponding to
the highest quality improvement rate is the optimal cutting
times. As can be seen from Fig. 11a, with the increase of the
quality be obtained at the least processing time, thus maximiz- number of cutting, the surface quality improvement rates of
ing the benefit. The processing time required for each scheme both trimming-cutting and deepening-cutting are gradually
is as follows: reduced. That is to say, the two kinds of multipass cutting all
As shown in Eqs. 7 and 8, in order to weigh the processing achieve the best surface quality improvement rate when the
time and cutting quality, the ratio of the reduction of surface number of cutting times is two. Therefore, as far as the surface
roughness to the increase of processing time is taken as the quality is concerned, the optimal cutting times of the two
surface quality improvement rate, and the ratio of the reduc- kinds of multipass cutting are both two. From Fig. 11b, it
tion of kerf taper to the increase of processing time is taken as can be found that with the increase of cutting times, the taper
the taper improvement rate. improvement rates of trimming-cutting and deepening-cutting
R1 −Rn increase first and then decrease. When the number of cutting
I Rn ¼ ð7Þ times is three, the taper improvement rate is the highest.
T n −T
Therefore, as far as the kerf taper is concerned, the optimal
cutting times of the two kinds of multipass cutting are both
three. In addition, as a whole, the quality improvement rate of
a 0.35 deepening-cutting is always better than that of trimming-
Improment of roughness(μm/s)

Trimming-cutting cutting.
0.3
Deepening-cutting
0.25

0.2
4 Conclusion
0.15

0.1 There are some defects in the cutting section of abrasive water
jet. In addition to several widely accepted methods, multipass
0.05
abrasive water jet cutting can also effectively improve these
0 defects. In this paper, AISI 304 stainless steel was used as a
2 3 4
Cutting times workpiece, the surface quality and kerf taper of the section
b after multipass abrasive water jet cutting with different cutting
0.35 times were analyzed. On this basis, the concept of quality
Improment of kerf taper(deg/s)

0.3 improvement rate was put forward, and the optimal cutting
0.25 times for surface quality and kerf taper were determined by
weighing the cutting quality and processing efficiency. The
0.2 Trimming-cutting
conclusions are as follows:
0.15 Deepening-cutting

0.1 (1) Two types of multipass abrasive water jet cutting were
clearly summarized and redefined. Both the two types of
0.05
multipass abrasive water jet cutting are to improve the
0 quality of the cutting by sacrificing some processing ef-
2 3 4
Cutting times ficiency. The section quality after trimming-cutting can
Fig. 11 Quality improvement rate. a Surface roughness improvement be greatly improved, but the processing time will be
rate. b Taper improvement rate multiplied. The improvement of section quality of

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1786 Int J Adv Manuf Technol (2018) 97:1779–1786

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