An investigation into the radial-mode abrasive waterjet turning process on high tensile steels

•We investigate into a new, high speed radial-mode abrasive waterjet turning process.•This process can significantly increase the material removal rate.•The study reveals new material removal mechanisms associated with the process.•It provides a deep understanding of the effects of process parameters.•A mathematical model for the depth of cut is developed for controlling the process.

A study of the radial-mode abrasive waterjet (AWJ) turning process is presented and discussed. An experimental investigation is carried out first to understand the material removal process and mechanisms as well as the effect of process variables (feed speed, water pressure, abrasive mass flow rate, nozzle tilt angle, and rotational surface speed) on the depth of cut, material removal rate (MRR) and surface roughness when turning an AISI4340 high tensile steel. It is found that this cutting mode is advantageous for high MRR, as compared to the traditional offset-mode turning, through the maximum use of jet energy for material removal as well as employing the optimum jet impact angle and high workpiece surface speed. The most efficient conditions to maximize depth of cut are found to be at the normal jet angle, higher water pressure, higher surface speed and lower feed speed. Yet, lower surface speed is not good for either MRR or surface quality. At high surface speeds, increasing the depth of cut always comes at the expense of poorer surface quality. In order to estimate the depth of cut on a mathematical basis, a dimensional analysis has then been conducted and a model for the depth of cut has been developed and verified. The model predictions are found to be in good agreement with the experimental results with an average error of 0.2%.