Thermodynamic analysis of material removal mechanisms indicates that an ideal tool for shaping of materials is a high energy beam, having infinitely small cross-section, precisely controlled depth, and direction of penetration, and does not cause any detrimental effects on the generated surface. The production of the beam should be relatively inexpensive and environmentally sound while the material removal rate should be reasonably high for the process to be viable. A narrow stream of high energy water mixed with abrasive particles comes close to meeting these requirements because abrasive waterjet machining has become one of the leading manufacturing technologies in a relatively short period of time. This paper gives an overview of the basic research and development activities in the area of abrasive waterjet machining in the 1990s in the United States.
Issue Section:
Nontraditional Processes
1.
Hashish, M., “Prediction Models for AWJ Machining Operations,” Proc. of 7th American Waterjet Conference, Seattle, WA, Aug. 28–31, 1993, pp. 205–216.
2.
Zeng, J., and Kim, T. J., “An Erosion Model of Polycrystalline Ceramics in Abrasive Waterjet Cutting,” 1996, accepted for Wear, to appear in Sept.
3.
Zeng, J. and Kim, T. J., “An Erosion Model for Abrasive Waterjet Milling of Polycrystalline Ceramics,” 1996 accepted for Wear, to appear in Dec.
4.
Momber
A. W.
Kovacevic
R.
Statistical Character of the Failure of Multiphase Materials due to High Pressure Waterjet Impingement
,” International Journal of Fracture
, Vol. 71
, 1995
, pp. 1
–14
.5.
Momber, A. W., Kovacevic, R., Pfeiffer, D., and Schunemann, R., “The Influence of Abrasive Grain Size Distribution Parameters on the Abrasive Waterjet Machining Process,” NAMRI/SME Transactions, NAMRC XXIV, May 21–24, 1996.
6.
Momber
A. W.
Kwak
H.
Kovacevic
R.
Investigations in Abrasive Waterjet Erosion Based on Wear Particle Analysis
,” 1996
, ASME Journal of Tribology
, Vol. 118
, pp. 759
–766
.7.
Finnie, I., “The Mechanism of Erosion of Ductile Metals,” ASME Proc. of 3rd National Congress on Applied Mechanics, 1958.
8.
Bitter
J. G. A.
A Study of Erosion Phenomena
,” Wear
, Vol. 6
, 1963
, pp. 5
–21
.9.
Hashish
M.
Material Properties in Abrasive Waterjet Machining
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 117
, November, 1995
, pp. 578
–583
.10.
Raju, S. P., and Ramulu, M., “Prediction of Hydro-Abrasive Erosive Wear During Abrasive Waterjet Cutting—Part I: A Mechanistic Formulation and its Solution,” Manufacturing Science and Engineering, ASME PED Vol. 68, 1994, 1, pp.
11.
Raju, S. P., and Ramulu, M., “Prediction of Hydro-Abrasive Erosive Wear During Abrasive Waterjet Cutting—Part II: An Experimental Study and Model Verification,” Manufacturing Science and Engineering, ASME PED Vol. 68, 1994, 1, pp.
12.
Momber, A. W., and Kovacevic, R., “Secondary Fragmentation in Waterjet Cutting of Brittle Multiphase Materials,” Waterjet Cutting Technology, ed. Allen, N. G., Mechanical Engineering Publications Ltd., London, England, 1994, pp. 139–150.
13.
Momber, A. W., Eusch, I., and Kovacevic, R., “Cutting Refractory Ceramics With Abrasive Waterjets—A Preliminary Investigation,” Proc. of 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1995, pp. 229–244.
14.
Yong
Z.
Kovacevic
R.
Simulation of Effects of Water-Mixture Film on Impact Contact in Abrasive Waterjet Machining
,” 1997
the International Journal of Mechanical Sciences
, Vol. 39
, No. 6
, pp. 729
–739
.15.
Momber, A. W., and Kovacevic, R., “Quantification of Energy Absorption Capability in Abrasive Waterjet Machining,” Proceedings of Institution of Mechanical Engineers, Part B, Journal of Engineering Manufacture, Vol. 209, 1995.
16.
Momber, A. W., and Kovacevic, R., “Calculation of Exit Jet Energy in Abrasive Waterjet Cutting,” Manufacturing Science and Engineering, ASME PED Vol. 68–1, pp. 361–366.
17.
Momber, A. W., Kovacevic, R., Kwak, H., and Mohan, R., “Experimental Estimation of Energy Dissipative Processes in Workpieces During Abrasive Waterjet Cutting,” Proc. 8th American Waterjet Conference, Houston, TX, August 26–29, 1995, pp. 187–206.
18.
Hashish
M.
1991
, “Characteristics of Surfaces Machined with Abrasive-Waterjets
,” ASME Journal of Engineering Materials and Technology
, Vol. 113
, July, 1991, pp. 354
–362
.19.
Hashish, M., “On the Modeling of Surface Waviness Produced by Abrasive Waterjets,” Proc. of 11th International Conference on Jet Cutting Technology, St. Andrews, Scotland, Sept. 8–10, 1992, pp. 17–34.
20.
Chao
J.
Zhou
G.
Leu
M. C.
Geskin
E.
Characteristics of Abrasive Waterjet Generated Surfaces and Effects of Cutting Parameters and Structure Vibration
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 117
, Nov., 1995
, pp. 516
–525
.21.
Kovacevic
R.
Mohan
R.
Zhang
Y. M.
Cutting Force Dynamics as a Tool for Surface Profile Monitoring in AWJ
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 117
, May, 1995
, pp. 340
–350
.22.
Kovacevic, R., and Beardsley, H. E., “On-Line Monitoring the Quality of the Surface Cut by the Abrasive Waterjet,” MR90-535, Proc. of 4th International Grinding Conference, Dearborn, MI, Oct. 9–11, 1990.
23.
Raju, S. P., and Ramulu, M., “A Transient Model for Material Removal in the Abrasive Waterjet Machining Process,” Proc. of 7th American Waterjet Conference, Seattle, WA, Aug., 1993, pp. 141–155.
24.
Kovacevic
R.
Mohan
R.
Zhang
Y. M.
Stochastic Modeling of Surface Texture Generated by High-Energy Jets
,” Proc. of Instn. Mech. Engrs, Part B, Journal of Engineering Manufacture
, Vol. 207
, 1993
, pp. 129
–140
.25.
Arola
D.
Ramulu
M.
Micromechanisms of Material Removal in Abrasive Waterjet Machining
,” Processing of Advanced Materials
, Vol. 4
, No. 1
, 1994
, pp. 37
–47
.26.
Hashish, M., 1995, “Development of an AWJ Deep Hole Drilling System for Metals,” Proc. 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1995, pp. 377–388.
27.
Kwak, H., Kovacevic, R., and Mohan, R., “Monitoring of AWJ Drilling of Ceramics Using AE Sensing Technique,” 1996 accepted for 13th International Conference on Jetting Technology, Sardinia, Italy, Oct. 29–30.
28.
Yong
Z.
Kovacevic
R.
Fundamentals of Constructing Particle-Laden Flow by Fractal Point Sets and Predicting 3D Solid Erosion Rates
,” The International Journal of Chaos, Solitons, & Fractals
, Vol. 8
, No. 2
, 1997
, pp. 207
–220
.29.
Ramulu
M.
Dynamic Photoelastic Investigation on the Mechanics of Waterjet and Abrasive Waterjet Machining
,” Optics and Lasers in Engineering
, Vol. 19
, No. 1–3
, 1993
, pp. 43
–65
.30.
Yen, H., Wang, F. X., and Ramulu, M., “An Optical Investigation on the Abrasive Waterjet Penetration Process,” Proc. of 7th American Water Jet Conference, Seattle, WA, pp. 65–70, Aug. 1993.
31.
Ansari, A. I., and Hashish, M., “On the Modeling of Abrasive Waterjet Turning,” Jet Cutting Technology, A. Lichtarowicz, ed., Kluwer Academic, Boston, 1992, pp. 555–576.
32.
Sheridan, M., Taggart, D. G., and Kim, T. J., “Screw Thread Machining of Composite Materials Using Abrasive Waterjet Cutting,” Manufacturing Science and Engineering, ASME PED Vol. 68–1, 1994, pp. 421–432.
33.
Sheridan, M., Taggart, D. G., Kim, T. J., and Wen, Y., “Microstructural and Mechanical Characterization of Threaded Composite Tubes Machined Using AWJ Cutting,” Proc. 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1995, pp. 245–258.
34.
Kovacevic, R., Mohan, R., and Hirscher, J., “Rehabilitation of Concrete Pavement Assisted with Abrasive Waterjets,” Jet Cutting Technology, A. Lichtarowicz, ed., Kluwer Academic, Boston, 1992, pp. 425–442.
35.
Zeng, J., and Kim, T. J., “Development of an Abrasive Waterjet Kerf Cutting Model for Brittle Materials” Jet Cutting Technology, A. Lichtarowicz, ed., Kluwer Academic, Boston, 1992, pp. 483–501.
36.
Zeng
J.
Kim
T. J.
Machinability of Engineering Materials in Abrasive Waterjet Machining
,” International Journal of Waterjet Technology
, Vol. 2
, No. 2
, 1995
, pp. 103
–110
.37.
Chung, Y., Geskin, E. S., and Singh, P. J., “Prediction of the Geometry of the Kerf Created in the Course of Abrasive Waterjet Machining of Ductile Materials,” Jet Cutting Technology, ed. A. Lichtarowicz, Kluwer Academic, Boston, 1992, pp. 525–535.
38.
Momber
A. W.
Kovacevic
R.
Fracture of Brittle Multiphase Materials by High Energy Water Jets
,” The Journal of Materials Science
, (31
) 1996
, pp. 1081
–1085
.39.
Kovacevic
R.
Monitoring the Depth of Abrasive Waterjet Penetration
,” International Journal of Machine Tools and Manufacture
, Vol. 32
, No. 5
, 1992
, pp. 725
–736
.40.
Kovacevic
R.
Fang
M.
Modeling of the Influence of the Abrasive Waterjet Cutting Parameters on the Depth of Cut Based on Fuzzy Rules
,” International Journal of Machine Tools and Manufacture
, Vol. 34
, No. 1
, 1994
, pp. 55
–72
.41.
Mohan, R., Momber, A. W., and Kovacevic, R., “On-line Monitoring of Depth of AWJ Penetration Using Acoustic Emission Technique,” Waterjet Cutting Technology, N. G. Allen, ed., Mechanical Engineering Publications Ltd., London, England, 1994, pp. 649–664.
42.
Hashish, M., “Three-Dimensional Machining with Abrasive Waterjets,” Waterjet Cutting Technology, ed. N. G. Allen, Mechanical Engineering Publications Ltd., London, England, 1994, pp. 605–633.
43.
Kovacevic, R., and Yong, Z., “Modeling of 3D Abrasive Waterjet Machining—Part I Theoretical Basis,” 1996, Jetting Technology, Institution of Mechanical Engineers, England, pp. 73–82.
44.
Yong, Z., and Kovacevic, R., “Modeling of 3D Abrasive Waterjet Machining—Part II Simulation of Machining,” 1996, Jetting Technology, Institution of Mechanical Engineers, England, pp. 83–89.
45.
Hashish, M., “Advances in Fluidjet Beam Processing,” Proc. 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1995, pp. 487–503.
46.
Ohadi
M. M.
Ansari
A. I.
Hashish
M.
Thermal Energy Distributions in the Workpiece During Cutting with an Abrasive Waterjet
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 114
, Feb., 1992
, pp. 67
–73
.47.
Kovacevic
R.
Mohan
R.
Beardsley
H. E.
Monitoring of Thermal Energy Distribution in Abrasive Waterjet Cutting using Infrared Thermography
,” 1996
, ASME Journal of Manufacturing Science and Engineering
, Vol. 118
, No. 4
, pp. 555
–563
.48.
Kovacevic
R.
Evizi
M.
Nozzle Wear Detection in Abrasive Waterjet Cutting Systems
,” Materials Evaluation
, Vol. 48
, Mar. 1990
, pp. 348
–353
.49.
Kovacevic
R.
Sensing the Abrasive Waterjet Nozzle Wear
,” International Journal of Waterjet Technology
, Vol. 2
, No. 1
, 1994
, pp. 1
–10
.50.
Kovacevic, R., “Development of an Opto-Electric Sensing System to Monitor the Abrasive Waterjet Nozzle Wear,” Sensors, Controls, and Quality Issues in Manufacturing, 1991, pp. 73–81.
51.
Kovacevic, R., Wang, L., and Zhang, Y. M., “Detection of Abrasive Waterjet Nozzle Wear Using Acoustic Signature Analysis,” Proc. of 7th American Waterjet Conference, Aug. 28–31, Seattle, WA, 1993, pp. 217–231.
52.
Kovacevic, R., and Zhang, Y. M., “On-line Fuzzy Recognition of Abrasive Waterjet Nozzle Wear,” Jet Cutting Technology, ed. A. Lichtarowicz, Kluwer Academic, Boston, 1993, pp. 329–345.
53.
Mohan, R., Kovacevic, R., and Damarla, T. R., “Real-Time Monitoring of AWJ Nozzle Wear Using Artificial Neural Network,” NAMRI/SME Transactions, NAMRC XXII, 1994, pp. 253–258.
54.
Kim, T. J., and Constantino, H., “Effect of Nozzle Length on Performance and Wear in Abrasive Waterjet Systems,” Proc. of 4th PRIC—WJT ’95, 1995, pp. 491–502.
55.
Nanduri, M., Taggart, D. G., Kim, T. J., Ness, E., and Risk, E., “Effect of Offset Bores on The Performance and Life of Abrasive Waterjet Mixing Tubes,” Proc. 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1995, pp. 459–472.
56.
Whalen, J. M., “Application of Advanced Abrasive Waterjet Machining at GE Aircraft Engines,” Proc. of 7th American Waterjet Conference, Aug. 28–31, Seattle, WA, 1993, pp. 883–897.
57.
Geskin, E. S., Tismenetskiy, L., and Li, F., “Development of Ice Jet Machining Technology,” Proc. 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1995, pp. 671–680.
58.
Kovacevic, R., Apparatus and Method of High Pressure Waterjet Assisted Cooling/Lubrication in Machining, 1994 U.S. Patent No. 5,288,186.
59.
Kovacevic
R.
Cherukuthota
C.
Mohan
R.
Improving Milling Performance with High Pressure Waterjet Assisted Cooling/Lubrication
,” ASME JOURNAL OF ENGINEERING FOR INDUSTRY
, Vol. 117
, Aug., 1995
, pp. 331
–339
.60.
Kovacevic, R., and Mohan, R., “Investigation of Effects of High Speed Coolant on Surface Grinding Performance,” MR95–213, Proc. of First International Machining and Grinding Conference of SME, 1995, Dearborn, MI.
61.
Mazurkiewicz, M., High Pressure Lubricooling Machining of Metals, 1992, U.S. Patent No. 5,148,728.
62.
Lindeke, R. R., Schoenig Jr., F. C., Khan, A. K., and Haddad, J., “Machining of α-β Titanium with Ultra-high Pressure through the Insert Lubrication/Cooling,” NAMRI/SME Transactions, NAMRC XIX, 1991, pp. 154–161.
63.
WJTA, “Liquid Nitrogen Jets Remove Rocket Propellent,” WJTA Jet News, ed. G. Savanick, Waterjet Technology Association, St. Louis, MO, May, 1994, pp. 1–4.
64.
Dunsky, C. M., and Hashish, M., “Feasibility Study of the use of Ultra-high Pressure Liquified Gas Jets for Machining of Nuclear Fuel Pins,” Proc. 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1994, pp. 505–517.
65.
Li, F., Geskin, E. S., and Tismenetskiy, L., “Feasibility Study of Abrasive Waterjet Polishing,” 1996 accepted for 13th International Conference on Jetting Technology, Sardinia, Italy, Oct. 29–30.
66.
Wu, S. S., and Kim, T. J., “An Application Study of Plain Waterjet Process for Coating Removal,” Proc. 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1995, pp. 779–792.
67.
Meng, P., Geskin, E. S., Tismenetskiy, L., and Leu, M. C., “Improvement of the Waterjet Based Precision Cleaning Technology,” Proc. 8th American Waterjet Conference, Houston, TX, Aug. 26–29, 1996, pp. 751–764.
68.
Meng, P., Geskin, E. S., Leu, M. C., and Tismenetskiy, L., “Waterjet Insitu Reactor Cleaning,” 1996, accepted for 13th International Conference on Jetting Technology, Sardinia, Italy, Oct. 29–30.
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