Waterjet for metal cutting
Waterjet cutting is the most versatile and efficient process on the market. When using abrasive in waterjet it creates a clean cut that does not require a secondary finishing. Therefore abrasive waterjet is ideally suited for tough and lucrative applications such as titanium, stainless steel ,copper, brass, alloy , tool steel, with aluminum and steel being the most commonly cut materials. Waterjet is extremely powerful, capable of cutting up to 6″ thick stainless steel.
It’s very small diameter cutting stream (approximately 0.040″) allows it to produce tight corners, with very high tolerances. Waterjet is a “Cold Cutting” process that produces no heat affected areas or burnt edges. These factors mean that there is little or no secondary operation required for most applications.
Waterjet cutting is the most versatile and efficient cutting process in the line of cutting industry.When we use abrasive in waterjets it creates a green cut that does not require a secondary finishing Therefore, abrasive waterjets are ideal for metal cutting on products such as aluminum, steel cutting, stainless steel, tool steel, titanium, brass, copper, alloys, and any other exotic material.
Abrasive waterjets can cut metal up to 8" thick and do not leave a heat affect zone. Abrasive waterjets also cut intricate parts quickly with high precision, keeping a tolerance ranging from 0.003 to 0.005.Due to there is absolutely no mechanical stress, heat distortion or heat-affected zone , secondary processing can be eliminated in many cases. Material can be stacked to increase productivity.
Also waterjets cut with a little kerf, parts can be tightly nested or common-line cut so raw material usage is maximized. This means less scrap on your floor and you can get more profits .Water jet cutting is strong enough to cut through nearly any material. Abrasive must be used with high pressure water in order to cut such strong material. Unlike pure water jet cutting, abrasive cutting uses garnet because water alone is not strong enough. These, rather than the water pressure, erode the metal. The water jets are thirty times stronger than the pressure of a car wash nozzle to cut metals like titanium, steel, stainless steel, aluminum, brass, iron and even hardened metals.
• Exotic materials including titanium and alloy steels are easily cut with no need to drill holes.
• Waterjet will pierce straight through stacked sheets, plastic coated materials, composite materials, ceramics, and just about any other materials known to man.
• Set up times and changes are extremely quick and simple.
Water jet cutting is strong enough to cut any material, cutting metal is very popular. Garnet must be used with high pressure water in order to cut such strong and resistant material. Unlike pure water jet cutting, abrasive cutting uses garnet because water alone is not strong enough. These, rather than the water pressure, erode the metal. The water jets are thirty times stronger than the pressure of a car wash nozzle to cut metals like titanium, steel, stainless steel, aluminum, brass, iron and even hardened metals.
Water jet metal cutting produces little scrap or waste metal and is considered highly accurate. The aerospace, automotive, transportation, engineering and construction industries all use water jet cutting products made of metal. Cars, airplanes, trains, submarines and busses are all made of metal parts that got their shape from water jet cutting. Factory machinery, tools and all sorts of irregularly shaped metal parts are also cut by water jets. This process can create nearly any shape or design out of two dimensional metal sheets as thick as four inches. A select few machines can cut multiple layers or a single sheet that is up to ten inches thick.Modern water jet cutting machines are fully automated and use CNC (computer numerical controlled) or industry PC software. A designer’s drawing is downloaded into software, which then follows it to cut the sheet metal to that shape. The sheet metal may be shaped into an intricate or unusual design or have holes rapidly drilled into it. This process generates no heat, which prevents the metal material’s properties like color, strength and chemical resistance from being altered; for this reason, water jet cutting is considered a cold working process. It is safer since operators are not needed to the extent they are in other cutting processes, and no dust or particles that can be inhaled by workers are produced. Labor costs are therefore low. Water jet cutting is a fast process with a high rate of accuracy and repeatability; high volumes of products are made. The finished product requires little or no secondary processing because the cut has no burrs or rough edges.
Metal Cutting FAQ’S• How fast can the material be cut?
The cutting speed is determined by the following factors: Pump pressure, efficiency of high pressure generation and cutting head configuration, material thickness and properties, desired cutting edge quality, orifice diameter, abrasive quantity and abrasive quality.• How thick can a waterjet cut?
It varies with the softness or hardness of the material being cut. This can range anywhere from a .001 up to 12 thick.Hard materials are normally cut within a .001 to 3.0 range. This does not mean Stainless Steel or stone with a 4 or 5-inch thickness cannot be cut with a waterjet. It all depends on the purpose for which cutting is done (i.e. prototype, production, etc.), as well as the system operating conditions.
• What about angle faults along the cut edge?
Depending on the requirements as regards cutting edge quality, excellent angle accuracy can be achieved by adjusting the pump pressure, the abrasive flow rate and the cutting speed accordingly. There are also software-based guiding systems on the market that help optimize angular accuracy, by adjusting the angle of the abrasive cutting head.
• What is unique about waterjet compared to other cutting technologies?
Waterjet allows tremendous flexibility and versatility in manufacturing and provides for more cutting possibilities. Simply put, waterjet cutting is by far, the most flexible and desirable technology for cutting and delivers results with amazing reliability.
• How does a waterjet work?
There are two main steps involved in the waterjet cutting process. First, the ultra-high pressure pump or intensifier generally pressurizes normal tap water at pressure levels above 40,000 psi (2760 bar); to produce the energy required for cutting. Second, water is then focused through a small precious stone orifice to form an intense cutting stream. The stream moves at a velocity of up to 2.5 times the speed of sound, depending on how the water pressure is exerted.