A Study of Kerf Characteristics in Abrasive Waterjet Machining of Graphite/Epoxy Composite

Abstract

Kerf geometry, kerf wall features, and cutting front characteristics of an Abrasive Waterjet (AWJ) machined Graphite/Epoxy (Gr/Ep) laminate were studied. A macroscopic analyses suggests that geometrical features associated with AWJ machining of Gr/Ep laminates are influenced by three macro regions along the cutting depth. The presence of these regions, including initial damage at jet entry, smooth cutting, and rough cutting near the jet exit, depends on the operating conditions. Design of experiments and analysis of variance were used to determine the effect of cutting parameters on kerf characteristics and to develop empirical models for kerf profile and features of the three distinct macroscopic regions. Cutting front analysis revealed that the mechanisms of material removal in AWJ machining of Gr/Ep do not change over the jet penetration depth. In general, high quality uniform cuts may be obtained by minimizing initial damage at the jet entry and by extending the smooth cutting region beyond the laminate thickness through the appropriate choice of cutting parameters.