Optimizing Accuracy of Abrasive Waterjet Cutting System: A Comprehensive Study on Mechanical and Software Compensation Strategies on 5-Axis CNC Waterjet Cutting Machine and Analysis Using Design FMEA

Abstract

Abrasive Waterjet cutting technology is more environmentally friendly than other methods like plasma and laser cutting. As a cold cutting method, it does not use flammable gases. Furthermore, it uses water and natural garnet as abrasive materials. The amount of waste is significantly lower compared to other methods. This study aims to increase cutting speed and efficiency while lowering carbon emissions by controlling the taper angle and enhancing machine sensitivity. The primary objective of this study was to optimize errors caused by the kerf and the taper angle in a waterjet cutting machine, both mechanically and during the cutting process. The goal of increasing precision was achieved successfully. A 10 mm thick SS314 Steel was processed using a CNC waterjet cutting device. Mechanical compensation was performed using a laser-based algorithm that measured and compensated for values at 10 mm intervals along the X and Y axes. After determining the waterjet's taper angle, the 5-axis cutting head was aligned perpendicular to the edge to ensure accuracy. The most efficient cutting parameters were found to be a pressure of 3.750 bar, an abrasive flow rate of 0.4 kg/m, a 1.02 mm nozzle, a 0.35 mm orifice, and 80 mesh garnet abrasive. The cutting speed was set at 300 mm/min. The taper angle was 1 degree, and the 5-axis machining head was positioned perpendicularly to the material's edge. Cutting was performed by tilting the head by 1 degree to effectively eliminate the taper angle effect. Design FMEA, as defined by the FMEA Tables of the IATF 16949 Automotive Standard, is typically used to identify the most critical characteristics. The patent for this original study is registered with the Patent Office (Patent no: TR 2018 20101). The improvements in cutting angle and precision have increased machine efficiency, which in turn has led to higher cutting speeds and reduced carbon emissions. By controlling the cutting angle, a thinner kerf is created, which leads to a reduction in waste.

Keywords

• Taper angle
• High precision
• Compensation
• Sustainability
• Automation
• Machine design

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