Abrasive waterjet (AWJ) near-net-shape fabrication including AWJ-Milling is a promising non-conventional manufacturing method with advantages for cutting difficult to machine materials. As for AWJ cutting, it is necessary to consider the ratio between the manufacturing time and the workpiece's quality before applying these methods. This ratio is strongly influenced by the AWJ's jet deflection, depending on the AWJ's energy. In this paper a model allowing to predict the kerf formation based on AWJ energy is presented. To study the effects of the AWJ's jet deflection, the AWJ energy is reproduced by a primary and a secondary jet and thus by a primary and secondary material removal. The model was calibrated on titanium aluminide for straight trajectories. The kerf depth and kerf distribution were measured and calculated for curved trajectories. The results reveal that the model reproduces the effects of the kerf formation appropriately. In addition, the model allows to derive strategies to adapt the process and increase the effectiveness of AWJ near-net-shape fabrication.
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