Integrated error modeling for abrasive waterjet cutting at various nozzle tilt angle

The research investigates the specific impact of high-pressure abrasive waterjet (AWJ) on the cutting accuracy of circular trajectories. The coupling relationship between the kerf taper and the jet lag of the cutting front profiles is analyzed. Thus, an integrated error model for abrasive waterjet cutting of circular trajectories is innovatively established, which can predict the deformation of the circular arc trajectory not only at right angles but also at tilt angles. Cutting experiments at vertical angles were conducted, with a maximum prediction accuracy of 2.41%. Besides, arc trajectories with different diameters were conducted with a prediction accuracy of 2.26%. In order to reduce the deformation error of arc trajectories, compensation experiments for nozzle tilt ranging from 76° to 94° were carried out. The experimental results showed that when the nozzle was tilted in the direction opposite to the traverse speed up to half of the maximum deviation angle at the jet outlet point, the maximum deformation of arc trajectories was 1.218 mm, which was reduced by 0.532 mm compared to the case of vertical incidence, and the cylindricity increased by 31.74%. This adjustment can meet the precision requirements for cutting thick materials with abrasive waterjet.