Modellierung der Schnittgeometrie beim Schneiden mit dem Wasserabrasivstrahl

Abrasive waterjet cutting comprises already today many applications in high precision and near net-shaping manufacturing of high alloy steels and light metals. These applications require currently a high degree of expertise and preparation by the operator. The objective of this thesis is therefore to develop methods and tools that can reduce the necessary amount of preparation through modeling of the geometrical outcome and optimizing the process. For this the fundamental erosion processes are modeled and simulated leading to a complete model of erosion behavior in the different zones of the cutting process. These models are experimentally verified utilizing newly developed approaches to analysis of the static and dynamic erosion behavior at the cutting front. Based on these findings, two practical approaches to optimizing both quality and performance of cutting operation with abrasive waterjets are elaborated. In this thesis new approaches to analysis and modeling of the cutting process with abrasive waterjets were pioneered that lead to possibilities for new applications and optimization of the process. The new process model is capable of picturing the underlying fundamental processes and can also serve as a basis for geometrical modeling of the cutting kerf and for optimization of the process. With its simple integration in recent software the model can support the user in significantly improving precision of his cutting operation as well as reducing laborious optimization test cuts. The results of this thesis and the development of new approaches to modeling of the abrasive waterjet cutting process has already today proven a great potential in optimizing the cutting process and making 3D precision cutting possible even in industrial environment, leading to improved performance, reliability and usability of the process which will eventually lead to new applications and thus new markets of this innovative technology