Integrated Geometric Confinement and Ejection-Driven Drainage Flow for Splash Suppession in High-Speed Abrasive Waterjet Machining

Xianding Xue; Oleksandr Salenko

doi:10.20535/2521-1943.2025.9.4(107).345010

Authors

Xianding Xue National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute” , Ukraine https://orcid.org/0009-0004-5909-1573
Oleksandr Salenko National Technical University of Ukraine “Igor Sikorsky Kyiv Polytechnic Institute” , Ukraine https://orcid.org/0000-0002-5685-6225

DOI:

https://doi.org/10.20535/2521-1943.2025.9.4(107).345010

Keywords:

abrasive waterjet machining, splash suppression, Venturi effect, numerical simulation, fluid-structure interaction

Abstract

Abrasive waterjet machining (AWJM) is widely used in aerospace and precision manufacturing due to its cold-cutting nature. However, the residual high-energy jet column penetrating the workpiece frequently impacts the support structure, generating intense splashback that leads to surface contamination and secondary damage. To address this, we propose a composite anti-splash support structure integrating a concave bowl surface with a Venturi-induced negative pressure mechanism. Using VOF multiphase modeling combined with finite element validation, we elucidate the synergistic control mechanism: the curved bowl promotes wall-adherent liquid sliding to reduce radial momentum, while the Venturi throat creates a ~0.15 MPa negative pressure zone that captures droplets into the downstream channel for dissipation. Results demonstrate that compared to conventional supports, the design reduces mixture peak velocity by ~35%, decreases droplet diffusion height by 40%, and curtails radial spread by 30%, effectively constraining contamination areas. Static analysis further confirms the structure maintains high safety margins even under extreme loads. These outcomes not only enhance AWJM processing environments but also provide a validated engineering paradigm for high-speed fluid interaction control. Looking forward, the mechanism resonates with splash suppression needs in photolithography, food packaging, electronic encapsulation, and metal cutting, paving the way for a universal design and evaluation system for splash control in advanced manufacturing.

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