Quality prediction and process optimization in abrasive waterjet cutting of ultra‐thick carbon fiber reinforced polymer

Abstract Surface roughness and delamination extent are key indicators for assessing the surface quality of machined carbon fiber reinforced polymer (CFRP) laminates. This study conducted an in‐depth investigation on the uncontrollable surface quality of abrasive water jet (AWJ) machining of ultra‐thick CFRP. Considering the sensitivity of the laminate structure to the jet impact angle, an optimized response surface methodology was used to analyze the effects of process parameters on surface roughness. Additionally, the differences in surface roughness on both sides of the kerf under non‐orthogonal cutting were examined. Based on these analyses, a surface roughness prediction model was developed. Furthermore, the study comprehensively analyzed the effects of material mechanical properties and process parameters on delamination damage. Using dimensional analysis, a predictive model for the maximum delamination length, considering jet energy dissipation, was established. The novelty of this research is to reveal the difference in surface quality on both sides of the kerf under non‐orthogonal cutting, and to establish prediction models for surface roughness and delamination damage based on the energy dissipation characteristics of ultra‐thick CFRP AWJ machining. This research provides essential modeling foundations for enhancing the controllability of AWJ machining quality for ultra‐thick CFRP complex components. Highlights Surface roughness and delamination damage impact AWJ use for ultra‐thick CFRP. Non‐orthogonal cutting causes surface quality differences on kerf sides. A model for kerf surface roughness at any jet impact angle was established. The delamination mechanism in internal path cutting was analyzed. The delamination length model for ultra‐thick CFRP laminates was established.