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Remanufacturing and Advanced Machining
cut through virtually any material (Yogeswaran and Pitchipoo, 2020). Its application
is especially important in the case of polymeric foams, which have been applied
for many years, and sandwich structures with aluminum honeycomb cores, which
currently experience a significant and growing interest. This type of construction
consists of two thin facing layers separated by a core material. With the application
of a carbon fiber sheet for sandwich facings, it displays a high stiffness, high tensile
strength, low weight, high chemical resistance, high-temperature tolerance, and low
thermal expansion. Core shapes and core material can be of various types, including
perhaps the most popular honeycomb core that consists of very thin foils in the form
of hexagonal cells perpendicular to the facings. The “lightweight design” philosophy
is essential to the transportation (automotive, aerospace, shipbuilding) industries;
therefore, this type of new materials have been adopted and use of sandwich structures has steadily increased in recent years (Yogeswaran and Pitchipoo, 2020). On
the other hand, Uhlmann and Männel (2019) demonstrate the feasibility of AWJ in
near-net-shape fabrication of three difficult-to-cut materials, namely, titanium aluminide, type Ti-43,5Al-4Nb-1Mo 0,1B (TNM-B1), an MMC composite of a standard
titanium alloy Ti6Al4V with 5% titanium carbide (Ti64 + 5%TiC), and zirconium
dioxide (ZrO 2 ).
The first commercial waterjet cutting system was developed in 1971 to cut laminated paper tubes, and in 1980, the process was modified by adding abrasives to the
plain waterjet (PWJ). Thereafter, an abrasive waterjet (AWJ) was invented to cut
various industrial materials such as steel, glass, and concrete (Liu et al., 2019).
In the waterjet machining process, a material removed from a target workpiece
emerges through an erosive venture of abrasive particles traveling at a high velocity. Two primary models of material removal can be pointed out, namely cutting
and plowing deformation wear mechanisms, which depend on workpiece material
and properties. In this respect, a workpiece can be categorized as ductile, brittle, or
composite (Llanto et al., 2021).
During interaction with ductile materials, such as metals, erosion can occur
through repeated plastic deformation and cutting action. For brittle materials, the
erosion process is predominantly realized through crack propagation and chipping.
In the case of composite materials, abrasives penetrate the material and produce
breakages that initiate the formation of cracks, which in turn results in delamination. In any case, the erosion mechanism allows for diverse functions of waterjet processing, such as cutting, milling, turning, grinding, drilling, and polishing
(Llanto et al., 2021). Abrasive water jet can be successfully used in a remanufacturing process, e.g., to clean components like engine cylinders to be remanufactured
(Dong et al., 2014).
Essentially, the abrasive waterjet machining technology uses a jet of high pressure
and velocity, water, and abrasive slurry to cut a target material. The process uses a
fine-bore nozzle and an orifice of diameter about 0.2–0.3 m to form a coherent, highvelocity jet which has a pressure of up to 400 MPa and a velocity of up to 1,000 m/s.
Diameters of the orifice range from 0.08 to 0.8 mm and it is commonly made of sapphire, ruby, or diamond (Saravanan et al., 2020). Figure 1.16 presents cutting heads
for plain or pure waterjet and abrasive waterjet machining. It should be emphasized
Remanufacturing and Advanced Machining
cut through virtually any material (Yogeswaran and Pitchipoo, 2020). Its application
is especially important in the case of polymeric foams, which have been applied
for many years, and sandwich structures with aluminum honeycomb cores, which
currently experience a significant and growing interest. This type of construction
consists of two thin facing layers separated by a core material. With the application
of a carbon fiber sheet for sandwich facings, it displays a high stiffness, high tensile
strength, low weight, high chemical resistance, high-temperature tolerance, and low
thermal expansion. Core shapes and core material can be of various types, including
perhaps the most popular honeycomb core that consists of very thin foils in the form
of hexagonal cells perpendicular to the facings. The “lightweight design” philosophy
is essential to the transportation (automotive, aerospace, shipbuilding) industries;
therefore, this type of new materials have been adopted and use of sandwich structures has steadily increased in recent years (Yogeswaran and Pitchipoo, 2020). On
the other hand, Uhlmann and Männel (2019) demonstrate the feasibility of AWJ in
near-net-shape fabrication of three difficult-to-cut materials, namely, titanium aluminide, type Ti-43,5Al-4Nb-1Mo 0,1B (TNM-B1), an MMC composite of a standard
titanium alloy Ti6Al4V with 5% titanium carbide (Ti64 + 5%TiC), and zirconium
dioxide (ZrO 2 ).
The first commercial waterjet cutting system was developed in 1971 to cut laminated paper tubes, and in 1980, the process was modified by adding abrasives to the
plain waterjet (PWJ). Thereafter, an abrasive waterjet (AWJ) was invented to cut
various industrial materials such as steel, glass, and concrete (Liu et al., 2019).
In the waterjet machining process, a material removed from a target workpiece
emerges through an erosive venture of abrasive particles traveling at a high velocity. Two primary models of material removal can be pointed out, namely cutting
and plowing deformation wear mechanisms, which depend on workpiece material
and properties. In this respect, a workpiece can be categorized as ductile, brittle, or
composite (Llanto et al., 2021).
During interaction with ductile materials, such as metals, erosion can occur
through repeated plastic deformation and cutting action. For brittle materials, the
erosion process is predominantly realized through crack propagation and chipping.
In the case of composite materials, abrasives penetrate the material and produce
breakages that initiate the formation of cracks, which in turn results in delamination. In any case, the erosion mechanism allows for diverse functions of waterjet processing, such as cutting, milling, turning, grinding, drilling, and polishing
(Llanto et al., 2021). Abrasive water jet can be successfully used in a remanufacturing process, e.g., to clean components like engine cylinders to be remanufactured
(Dong et al., 2014).
Essentially, the abrasive waterjet machining technology uses a jet of high pressure
and velocity, water, and abrasive slurry to cut a target material. The process uses a
fine-bore nozzle and an orifice of diameter about 0.2–0.3 m to form a coherent, highvelocity jet which has a pressure of up to 400 MPa and a velocity of up to 1,000 m/s.
Diameters of the orifice range from 0.08 to 0.8 mm and it is commonly made of sapphire, ruby, or diamond (Saravanan et al., 2020). Figure 1.16 presents cutting heads
for plain or pure waterjet and abrasive waterjet machining. It should be emphasized