Exploration of Erosion Characteristics in Multi-step Machining by CFD-Assisted Abrasive Waterjet

Abstract

Abrasive water jet (AWJ) technology, predicated on the high-velocity mixing of air, water, and abrasive particles, is a critical technique for precision material removal. This study presents a comprehensive investigation into AWJ erosion mechanisms by integrating experimental observations with advanced Computational fluid dynamics (CFD) simulations. The inherent complexity of the three-phase erosion field, particularly regarding the evolution of stagnation zones at increased erosion depths, presents significant challenges for direct experimental observation. To overcome these limitations, an initial erosion channel profile obtained under controlled experimental conditions was employed as a boundary condition in CFD simulations to model the trajectory of abrasive particles accurately. The simulations facilitate the prediction of successive erosion channel profiles by elucidating the influence of stagnation zones on abrasive particle refraction during both normal and inclined multi-step erosion processes. Comparative analysis between the CFD results and experimental data confirms that stagnation zones play a pivotal role in modulating AWJ erosion energy. This work not only refines the predictive modeling of AWJ-induced erosion but also deepens the fundamental understanding of the erosion process through detailed examination of stagnation zone dynamics.