An innovative method to perform maskless plain waterjet milling for pocket generation: A case study in Ti-based superalloys

This paper presents an innovative methodology/jet path on which plain waterjet (PWJ) can generate pockets of good dimensional/geometrical definition (minimised under/over-erosion) while the proposed method leads to the avoidance of grit embedment on the target workpiece and the elimination of extra cost and time related to the use of mask. The novelty of the paper relies on the proposal of jet-path strategy that minimises the variations in jet dwell time by providing continuous relative movement during the jet-part interaction (through minimisation of accelerations/decelerations of the machine head) and by removing a controlled amount of material in a series of layers using special techniques. The proposed method is powerful in its approach from which it ensures (quasi)equal exposure time for each zone of material over which the jet passes, so that the jet path is totally contained within the form to be generated; hence, no masking is necessary to define the contour/shape. This approach has been employed for generating pockets on two Ti-based superalloys commonly used in aerospace industries, followed by dimensional, geometrical and surface quality analysis. The results proved that this approach can produce milled surfaces of straightness of the pocket bottom (<200 μm), tolerance on depth of cut per layer (<20 μm), tolerance on the radii at the bottom of the pockets (<100 μm), surface roughness (Ra=414 μm) and waviness (Wa=1013 μm) characteristics in conditions of high surface integrity (no cracks, contaminations, etc.).