Finite element modelling of a single-particle impact during abrasive waterjet milling

In this study, an attempt has been made to study the basic aspects of abrasive waterjet (AWJ) controlled-depth process using the finite element (FE) method to predict the profile of the crater produced by single particle impact rather than to perform first the simulation of full jet plume impingement. It is believed that the first should be a sine-qua-non-condition for developing the multiparticle impingement simulation to address the real-life AWJ milling process. The main objective of this article is to simulate and experimentally validate the profile of the craters at different impact angles of particles accelerated with waterjet. The workpiece material modelled is a Ti-based superalloy (Ti–6Al–4V) extensively used in the aerospace industry. The current model takes into account the effects of high-strain rate plastic deformation and adiabatic heating. The FE-simulated profiles of the craters are found to be in good agreement with experimentally generated data. The presented work provides a good (experimentally validated) basis for further FE modelling of the AWJ milling process, where influences such as particles’ shape, rotation, and multiple overlapping impacts can be further investigated.