IRON KNIGHTS METAL WORKING

Water Jet Cutter

History

In the 1950s, forestry engineer Norman Franz experimented with an early form water jet cutting to cut wood. However, the technology did not advance especially until the 1970 when Mohamed Hashish created a technique to add abrasives for water-jet cutter. Today the water jet is unparalleled in many aspects of cutting and has changed the way many products are manufactured. Many types of jets water exist today, including running water jets, abrasive water jets, percussive water jets, cavitation jets and hybrid jets.

Operation

The cutter is commonly connected to a water pump high pressure which then pushes water from the nozzle of cut through the material by spraying with water jet at high speed. Additives in the form of suspended grit or other abrasives such as garnet and aluminum oxide can assist in this process.

Benefits

A major advantage of water jet cutting is the ability to cut material without interfering with the material's inherent structure as there is no "heat affected zone" or HAZ. Minimize the effects of heat allows metals to be cut without harming or changing intrinsic properties.

Water jet cutters are also capable of producing rather intricate cuts in the material. The court or the width of the cut can be changed by changing parts in the nozzle, and the type and size of abrasive. Typical abrasive cuts made with a cut in the range of 0.04 "to 0.05" (1.016 to 1.27 mm), but can be as narrow as 0.02 "(0.508 mm). courts do not normally abrasive 0.007" to 0.013 "(0.178 to 0.33 mm), but can be as small as 0.003 "(0.076 mm), which is approximately the size of a human hair. These small details can make cutters possible very small in a wide range of applications.

Water jet technology is considered "green." The water jets do not produce hazardous waste, reducing waste disposal costs. You can cut large pieces of reusable scrap material that might have been lost with the traditional cutting methods. The parts can be nested around maximizing the use of materials, and saves water jet material by creating very little cutting. Water jets use very little water (half gallon to approximately one gallon per minute depending on the size of the orifice of the cutting head), and the water used can be recycled using a closed loop system. The waste water is usually clean enough to filter out the drain. The garnet abrasive is a substance natural non-toxic that can be recycled for repeated use. Garnet usually can be disposed of in landfills. The water jets also remove dust particles air, smoke, gases and pollutants from cutting materials such as asbestos and fiberglass. This greatly improves the work environment and reduces the problems arising from exposure operator.

Versatility

A water jet cutting the creation of a specialized tool

Due to the nature of the cutting current can easily modify the stream of water can be used in almost all sectors, there many different materials that the water jet can cut. Some of them have unique characteristics that require special attention during the cut. Each material will be cut some unique characteristics that must be taken into account.

The materials commonly water-jet cutting include rubber, foam, plastic, composites, stone, ceramics, metals, food, paper and more. Materials that can not be cut with a jet of water are glass tempered, diamonds and certain ceramics.

Water jet cuts are not typically limited by the thickness of the material, and are able to cut materials more than eighteen inches (45 cm) thick. The penetrating power of these tools has led to the exploration of their use as anti-tank weapons, but because its short range and the advent of composite armor, the investigation was discontinued.

Availability

Commercial systems running water are available to manufacturers worldwide in a range of sizes and with water pumps capable of a range of pressures. Typical cutting machine waterjet have a work space as small as a few square meters, or even hundreds of square meters. Ultra high pressure pumps of water are available from a minimum of 40,000 psi (276 MPa) to 90,000 psi (621 MPa).

Process

There are six main characteristics of the process for water jet cutting:

Use a high-speed stream of particles abrasive suspended in a stream of ultra high pressure water (30,000 to 90,000 PSI) which is produced by a pump jet intensifier.

It is used for machining a wide variety of materials including heat sensitive materials, delicate or too hard.

It has no heat damage to the part surface or edges.

The nozzles are typically made of sintered boride.

Produces a slope of less than 1 degree in the majority of the cuts, which can be reduced or eliminated entirely by the delay of the cutting process.

Distance from the nozzle of the workpiece affects the size of the cut and material removal rate. Typical distance is 0.125.

The temperature is not much of a factor.

Quality Edge

the quality of the cutting edges of parts water jet is defined by numbers 1 5. Lower numbers indicate rougher edge finish, higher numbers are softer. For materials thin, the difference in cutting speed for Quality 1 could be up to three times faster than the speed of Quality 5. For thicker materials, quality 1 would be 6 times faster than quality 5. For example, 4 thick aluminum P5 would be 0.72 ppm (18 mm / min) and Q1 would be 4.2 ipm (107 mm / Min), 5.8 times faster.

Multi-axis cutting

Main article: mechanized multicore

A 5-axis water jet cutting head

A 5-axis waterjet Party

With recent advances in motion and control technology of water jet cutting 5 axis (abrasive and pure) has become a reality. When the normal axis in a stream of water is called X (back / forward), Y (left / right) and Z (up / down), a system usually add a 5 Axis axis (perpendicular angle) and C axes (rotation about Z axis). Depending on the cutting head, cutting the maximum angle to the axis can be anywhere from 55, 60, or in some cases 90 degrees from vertical. Such as cutting, 5 Axis opens a wide range of applications can be processed in a machine for water jet cutting.

A cutting head 5-axis can be used to cut the pieces of 4-axis, where the background geometry move a certain amount to produce the proper angle and the Z axis maintained at a height. This can be useful for applications such as the preparation of the welding bevel angle should be cut on all sides by a party later be welded, or for compensation where it is transferred cone angle cutting waste material - thus eliminating taper commonly found in water jet cut parts. A 5-axis head can cut pieces on the Z axis is also moving along with all other axes. This full 5-axis cutting is could be used for contour cutting on various surfaces of the parts together.

Due to the angles that can be cut, programs Parts may have to further cuts to free the blade. The attempt to slide a complex part in a severe angle of a plate can be difficult without cuts compensation.

References

^ About water jets, Retrieved on on 13/02/2010, http://www.webcitation.org/5nWaNTDGA, retrieved 13/02/2010.

^ "Company | Flow International Corporation Flowcorp.com http://www.flowcorp.com/about-flow.cfm Retrieved on 11/06/2009 ....

^ A b "Company." Jet Edge. http://www.jetedge.com/content.cfm?fuseaction=dsp_applications_101. Retrieved on 11/06/2009.

^ "Company | WARDJet. WARDJet.com. Http://www.wardjet.com/learnmore.asp. Accessed on 11/06/2009.

^ "90,000 psi Jet Edge X-Stream Waterjet intensifier pump. 25/01/2009. Http: / / www.jetedge.com/content.cfm?fuseaction=dsp_products_detail&product_ID=120. Retrieved on 01/25/2009.

^ "Company | Services global rebar." grswaterjet.co.uk. http://www.grswaterjet.co.uk/pumps.html. Retrieved on 08/09/2009.

^ "Relationship Parameters jet of water." http://www.wardjet.com/02-waterjet-relationship-parameters.html.

^ Abc "cutting 5 axis water jet." http://www.wardjet.com/5-axis.asp.

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Waterjets.org

How Water Jets Work, HowStuffWorks.com video

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