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<p>Abrasive waterjet (AWJ) machining is a sustainable, low-damage technique for improving surface quality and mechanical performance of engineering materials.However, conventional AWJ systems with straight nozzles encounter substantial limitations when processing components with intricate internal geometries. To address this issue, a novel deflection waterjet polishing (DWJP) technique is proposed, which distinguishes itself from conventional straight-nozzle AWJ systems by utilizing a specially designed nozzle with symmetrically arrayed deflection channels and a defined deflection angle.DWJP was validated through surface treatment experiments on the internal cavities of 316L stainless steel components. Numerical simulations were first carried out in Fluent to investigate the effects of deflection channel type and angles on the flow field distribution, abrasive particle trajectories, and erosion rates. Subsequently, experimental evaluations were conducted to assess improvements in surface quality. The results demonstrated that the optimal configuration, consisting of a double-hole array deflection channel combined with a 135° nozzle angle, led to a significant enhancement of waterjet performance.When applied to 316L stainless steel cavities, the DWJP process reduced the surface roughness to 0.49&#xa0;μm (a 68.6% reduction) and lowered the peak-to-valley difference to 2.9&#xa0;μm (a 73.43% reduction). Microstructural analyses revealed that micro-cutting, ploughing, and indentation constituted the dominant material-removal mechanisms. These findings demonstrate the feasibility of DWJP and underscore its potential for precise surface finishing of components with complex internal geometries.</p>

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Simulation optimization design and performance verification of a new abrasive waterjet deflection nozzle for machining internal cavity structure

  • 期刊论文

  • 发表日期：

    2025年11月15日

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  • Yipeng Li,
  • Chuanzhen Huang,
  • Zhen Wang,
  • Zhenyu Shi,
  • Longhua Xu,
  • Shuiquan Huang,
  • Meina Qu,
  • Zhengkai Xu,
  • Dijia Zhang,
  • Baosu Guo,
  • Tianye Jin,
  • Hanlian Liu,
  • Dun Liu,
  • Peng Yao

摘要

Abrasive waterjet (AWJ) machining is a sustainable, low-damage technique for improving surface quality and mechanical performance of engineering materials.However, conventional AWJ systems with straight nozzles encounter substantial limitations when processing components with intricate internal geometries. To address this issue, a novel deflection waterjet polishing (DWJP) technique is proposed, which distinguishes itself from conventional straight-nozzle AWJ systems by utilizing a specially designed nozzle with symmetrically arrayed deflection channels and a defined deflection angle.DWJP was validated through surface treatment experiments on the internal cavities of 316L stainless steel components. Numerical simulations were first carried out in Fluent to investigate the effects of deflection channel type and angles on the flow field distribution, abrasive particle trajectories, and erosion rates. Subsequently, experimental evaluations were conducted to assess improvements in surface quality. The results demonstrated that the optimal configuration, consisting of a double-hole array deflection channel combined with a 135° nozzle angle, led to a significant enhancement of waterjet performance.When applied to 316L stainless steel cavities, the DWJP process reduced the surface roughness to 0.49 μm (a 68.6% reduction) and lowered the peak-to-valley difference to 2.9 μm (a 73.43% reduction). Microstructural analyses revealed that micro-cutting, ploughing, and indentation constituted the dominant material-removal mechanisms. These findings demonstrate the feasibility of DWJP and underscore its potential for precise surface finishing of components with complex internal geometries.