XXXX Sympozjon “Modelowanie w mechanice”, Wisła 2001 Ashraf I. HASSAN and Jan KOSMOL Department of Machine Technology, Technical University of Silesia, Gliwice, Poland A NEW APPROACH OF VIRTUAL FINITE ELEMENT EXPERIMENTATION AS A MEANS FOR MODELING ADVANCED MACHINING PROCESSES Abstract: Despite the large number of models of advanced machining processes, such as abrasive waterjet machining (AWJM), which have been developed so far, there still has been confusion about the nature by which workpiece surfaces are eroded. The finite element method (FEM) could provide both qualitative and quantitative means in order to explain the AWJ erosion process. This paper presents an attempt to model the AWJM process using the powerful tool of the finite element method. The main objective is to develop an FE model which would enable to predict the depth of cut without any cutting experiments. In the new model, interaction of the abrasive particle with the workpiece material is traced at small time increments. The model accurately predicts the depth of cut as a result of AWJ impact and the FE results are in good agreement with experimental results. 1. INTRODUCTION Abrasive waterjet machining (AWJM) has been successfully used in the machining of a wide variety of different materials. Despite the large number of abrasive waterjet machining (AWJM) models developed so far [1-4], there still has been confusion about the nature by which workpiece surfaces are eroded. Up to date, there has been only few preliminary attempts for analyzing AWJM using the powerful tool of the finite element method (FEM) as shown in Table 1. Due to the shortcomings and simplicity of the these FE models, a more comprehensive nonlinear dynamic FE model is required to fully understand the mechanism of cutting in AWJ. A new approach of non linear dynamic modeling of AWJ using virtual FEM has been recently developed by the authors [11]. This approach consists of tracing the abrasive particle from its early exit from the mixing tube nozzle to its reflection from the surface after interaction with the material at small time intervals, e.g. 0.01 s. This method has proved to be very rewarding in explaining the mechanism of material removal and the overall behavior of the process. Using this method, the depth of AWJ kerf is now obtainable. In this model, the flow stress was chosen equal to the theoretical fracture strength i.e. (E/14) for steel. 2 EXPERIMENTAL WORK A two dimensional abrasive waterjet machine, Foracon model: ORCA 2000, is used in this work. The measuring machine used throughout this work for recording the workpiece depth of cut is Form Measuring Machine PG-2/200 M. Carbon steel St 3S, corresponding to Polish Standards PN-88/H-84020, was chosen as the workpiece material for the experiments. It has