A finite element-based model for pure waterjet process simulation

The utilization of abrasive waterjet (AWJ) cutting/drilling, and in particular its application into hard-to-cut materials, is growing. However, the mechanics of AWJ cutting is complex; the material removal process is not fully understood and, consequently, it has not been accurately modeled. In the current study, work was undertaken to mesh in a first stage the waterflow into the waterjet nozzle in order to use the finite element (FE) method to simulate the pure waterjet flow. The main objective is to investigate and analyze in detail the workpiece material behavior under waterjet impingement; a non-linear FE model (using LS-DYNA 3D code) has been developed, which simulates the erosion of the target material caused by the high-pressure waterjet flow. A combination of Eulerian–Langrangian elements is used for the waterjet and the target material, respectively, in order to handle their interaction. Damaged zones can be localized on impinged materials. Elements’ failure is handled by introducing a threshold strain after which Langrangian elements are removed. The results obtained from this numerical simulation (velocity profile, stress, erosion stages) show a good agreement with the results from previous experimental work that is available in bibliography. The next step of the research will be focused on the simulation of the whole procedure using various abrasives.