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https://doi.org/10.1007/s00170-018-2011-0
ORIGINAL ARTICLE
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
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
Workpiece AWJ
8
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
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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