Numerical investigation into high-pressure water-jet assisted orthogonal cutting of Ti–6Al–4V superalloy

This study presents a novel finite element modeling approach for high-pressure water-jet assisted (HPWJA) machining of Ti–6Al–4V alloy. A Coupled Eulerian–Lagrangian (CEL) model was developed to accurately capture the fluid–structure interaction between the high-velocity water-jet and the workpiece–tool interface—an aspect not adequately represented in previous studies. The proposed model simultaneously considers the mechanical impact and thermal effects induced by the high-pressure jet. Simulation results reveal that HPWJA machining significantly enhances performance, leading to up to 300 °C reduction in cutting temperature, approximately 45% shorter tool–chip contact length, and formation of smaller, discontinuous chips compared to dry cutting. These findings demonstrate the effectiveness of the CEL approach in predicting complex multiphysical interactions in assisted machining processes and provide new insights into the cooling and chip-breaking mechanisms of HPWJA machining of titanium alloys.