The kerf taper and cutting front drag are crucial factors limiting the abrasive waterjet (AWJ) machining of ultra-thick CFRP laminates. Therefore, this study investigated the variation patterns of kerf width and maximum cutting front drag with process parameters and established predictive models. The models accurately predicted kerf entrance width, kerf exit width, and maximum cutting front drag with R-squares of 0.9881, 0.9761, and 0.9791. Moreover, the influence of the key kinematic parameter of complex structure manufacturing - the jet impact angle on the kerf profile was analyzed from a geometric analysis. A numerical regression approach was employed to derive an energy dissipation function for CFRP laminate processing. A semi-analytical mathematical model was established based on energy balance theory. Under arbitrary jet impact angle, the kerf profiles on both sides are predicted with R-square of 0.9455 and 0.9525 respectively, and the cutting front drag profile is predicted with R-square of 0.9078.

中文翻译：

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基于分析模型预测超厚 CFRP 层压板水射流加工的几何形态

切口锥度和切削前阻力是限制超厚 CFRP 层压板磨料水射流 (AWJ) 加工的关键因素。因此，本研究研究了切缝宽度和最大切削前阻力随工艺参数的变化模式，并建立了预测模型。该模型准确预测了切缝入口宽度、切缝出口宽度和最大切割前阻力，R 平方分别为 0.9881、0.9761 和 0.9791。此外，还从几何分析的角度分析了复杂结构制造的关键运动学参数——射流冲击角对切缝轮廓的影响。采用数值回归方法推导出 CFRP 层压板加工的能量耗散函数。基于能量平衡理论建立了半解析数学模型。在任意射流冲击角度下，两侧切缝轮廓的预测R平方分别为0.9455和0.9525，切割前阻力轮廓的预测R平方为0.9078。