Numerical simulation for abrasive water jet machining based on ALE algorithm

In dealing with fluid impact and large deformation problems by traditional Lagrange grid, calculation failure often happens due to grid distortion. An abrasive water jet machining model is created to simulate the whole stage by software LS-DYNA from the jet into the nozzle to the workpiece material removal process using ALE (Arbitrary Lagrange-Euler) algorithm. The mesh for the abrasive and water is based on the ALE formulation, while the target mesh applies the Lagrange formulation. The effect of jet penetration is implemented by coupling the grids of ALE and Lagrange. The jet traverse speed is achieved by definition of the movement of ALE grid to reduce the mesh domain. The abrasive constitutive equations are also presented in this paper. The uniform mixture for abrasive and water is achieved by definition of volume percentage of the two materials in the initial ALE elements. Simulation results give the relationships between processing parameters and the cutting depth. The good agreement between simulation results and experimental data verifies the correctness of the simulation.