Exploration of erosion characteristics in multi-step machining by CFD-assisted abrasive waterjet

Yuan, Yemin (author), Wang, Jintao (author), Chen, Jianfeng (author), Yu, Yang (author), Xie, Youhao (author), Wang, Huixian (author), Chen, Yu (author)

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.

• Language: English
• Keywords: abrasive waterjet, computational fluid dynamics (CFD), stagnation zone, multi-step erosion
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FS - Faculty of Mechanical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2026
• Number of pages: Str. 144-157
• Numbering: Vol. 72, no. 5/6
• PID: 20.500.12556/RUL-184817
• UDC: 621.924.9
• ISSN on article: 0039-2480
• DOI: 10.5545/sv-jme.2025.1597
• COBISS.SI-ID: 284760323
• Publication date in RUL: 15.07.2026

Record is a part of a journal

• Title: Strojniški vestnik
• Shortened title: Stroj. vestn.
• Publisher: Zveza strojnih inženirjev in tehnikov Slovenije [etc.], = Association of Mechanical Engineers and Technicians of Slovenia [etc.
• ISSN: 0039-2480
• COBISS.SI-ID: 762116

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian
• Title: Raziskovanje značilnosti erozije pri večstopenjski obdelavi z abrazivnim vodnim curkom, podprto z računalniško dinamiko tekočin (CFD)

Abstract

Tehnologija abrazivnega vodnega curka (AWJ), ki temelji na mešanju zraka, vode in abrazivnih delcev pri visokih tlakih in hitrostih, predstavlja pomembno metodo za natančno odstranjevanje materiala. V tej raziskavi je predstavljena celovita analiza erozijskih mehanizmov AWJ, ki združuje eksperimentalna opazovanja in napredne simulacije računalniške dinamike tekočin (CFD). Zaradi kompleksnosti trifaznega erozijskega polja, zlasti razvoja stagnacijskih območij pri večjih globinah erozije, je neposredno eksperimentalno opazovanje zelo zahtevno. Za premagovanje teh omejitev je bil začetni profil erozijskega kanala, pridobljen v nadzorovanih eksperimentalnih pogojih, uporabljen kot robni pogoj v CFD-simulacijah za natančno modeliranje trajektorij abrazivnih delcev. Simulacije omogočajo napovedovanje zaporednih profilov erozijskih kanalov z razjasnitvijo vpliva stagnacijskih območij na spremembo smeri gibanja abrazivnih delcev pri večstopenjskem erozijskem procesu za primere, ko je smer vodnega curka normalno ali poševno orientirana glede na lego obdelovanca. Primerjalna analiza rezultatov CFD simulacij in eksperimentalnih podatkov potrjuje, da imajo stagnacijska območja ključno vlogo pri uravnavanju erozijske energije abrazivnega vodnega curka. Raziskava ne le izboljšuje napovedne modele erozije, povzročene z AWJ, temveč tudi poglablja temeljno razumevanje erozijskega procesa z natančno analizo dinamike stagnacijskih območij.

• Keywords: abrazivni vodni curek, računalniška dinamika tekočin (CFD), stagnacijsko območje, večstopenjska erozija