Title: Finite element analysis of material removal in AWJM using different material models and spatial distributions for garnet abrasives

Authors: Y. Abdelhameed; Ibrahem Maher; Jiwang Yan; Hassan El-Hofy; Mohsen A. Hassan

Addresses: Industrial and Manufacturing Engineering Department, Egypt-Japan University of Science and Technology (E-JUST), Borg El Arab 21934, Egypt; Department of Mechanical Engineering, Benha Faculty of Engineering, Benha University, Benha 13512, Egypt ' Industrial and Manufacturing Engineering Department, Egypt-Japan University of Science and Technology (E-JUST), Borg El Arab 21934, Egypt; Department of Mechanical Engineering, Faculty of Engineering, Kafrelsheikh University, Kafrelsheikh 33516, Egypt ' Department of Mechanical Engineering, Faculty of Science and Technology, Keio University, Yokohama 223-8522, Japan ' Department of Production Engineering, Faculty of Engineering, Alexandria University, Alexandria 21544, Egypt ' Industrial and Manufacturing Engineering Department, Egypt-Japan University of Science and Technology (E-JUST), Borg El Arab 21934, Egypt

Abstract: Garnet, the most widely used abrasive material in abrasive waterjet machining (AWJM), presents challenges in modelling its behaviour. Therefore, a finite element (FE) model was proposed to analyse the effect of using different material models and spatial distributions for garnet on the erosion behaviour of Al 7075-T6. Three popular material models were considered for garnet, including rigid, linear elastic, and tensile failure models, in addition to the Johnson-Holmquist (JH2) model. These four models were tested and compared for single and multiple particle impact under different waterjet pressures, abrasive mesh sizes, and impact angles. Furthermore, the effect of particle spatial distribution within the jet pass was examined. The model results demonstrated that using different material models for garnet significantly controls the erosion behaviour in AWJM. In addition, the radial distribution of the abrasive particles critically affected the erosion process and kerf geometry, while the axial distribution insignificantly influenced the erosion rate.

Keywords: abrasive waterjet; finite element simulation; garnet material model; spatial distribution of abrasive particles; material removal.

DOI: 10.1504/IJMMM.2025.147428

International Journal of Machining and Machinability of Materials, 2025 Vol.27 No.2, pp.121 - 144

Received: 13 May 2024
Accepted: 02 Sep 2024
Published online: 15 Jul 2025 *

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