Experimental evaluation of the physical properties required of abrasives for optimizing waterjet cutting of ductile materials

The results of investigations based on the tests with six mineral and one high density glass abrasives to identify the abrasive properties required for the optimum machining of ductile materials by abrasive waterjet cutting are presented. Equations derived from tests results for the rate of erosion and the abrasive mass flow rate, abrasive particle size, and abrasive particle density are presented. It is shown that above a certain abrasive density there is no improvement in rate of this type of erosion and that poly-crystalline abrasives are more effective than mono-crystalline abrasives of the same composition. There is also a linear relation between the Vicker's Hardness of an abrasive and the rate of erosion and that the more angular the abrasive particle edges, the greater the rate of erosion.For the combined deformation mode and cutting mode erosion of abrasive waterjet cutting, the effectiveness of an abrasive depends upon its relative hardness to that of the material being machine and if the difference is sufficiently large, the form or edges of an abrasive particle used may be of greater importance in determining the maximum cutting depth obtainable than that of the other physical abrasives properties.

► Effects of physical properties of abrasives in waterjet cutting are evaluated. ► Influence of abrasive: feed rate, size, density, hardness and BWI are quantified. ► Internal poly-crystalline abrasive particle affects deformation mode cutting rate. ► Effect of particle form prevails if abrasive is sufficiently harder than material cut.