A Water Jet Cutter
Content
A water jet cutter, also known as a water jet or waterjet, is an industrial tool capable of cutting a wide variety of materials using a very high-pressure jet of water, or a mixture of water and an abrasive substance. The term abrasivejet refers specifically to the use of a mixture of water and abrasive to cut hard materials such as metal or granite, while the terms pure waterjet and water-only cutting refer to waterjet cutting without the use of added abrasives, often used for softer materials such as food or rubber.[1] Waterjet cutting is often used during fabrication of machine parts. It is the preferred method when the materials being cut are sensitive to the high temperatures generated by other methods. Waterjet cutting is used in various industries including mining and aerospace for cutting, shaping, and reaming.
Operation
The cutter is commonly connected to a high-pressure water pump where the water is then ejected from the nozzle, cutting through the material by spraying it with the jet of high-speed water. Additives in the form of suspended grit or other abrasives, such as garnet and aluminium oxide, can assist in this process.
is no "heat-affected zone" (HAZ). Minimizing the effects of heat allows metals to be cut without harming or changing intrinsic properties.
Water jet cutters are also capable of producing intricate cuts in material. With specialized software and 3-D machining heads, complex shapes can be produced.[30]
The kerf, or width, of the cut can be adjusted by swapping parts in the nozzle, as well as changing the type and size of abrasive.
Water jets are capable of attaining accuracies down to 0.005″ (0.13 mm) and repeatabilities down to 0.001″ (0.025 mm).[30]
water jet cutting can reduce the amount of scrap material produced, by allowing uncut parts to be nested more closely together than traditional cutting methods.
Water jets use approximately one half to one gallon per minute (depending on the cutting head's orifice size), and the water can be recycled using a closed-loop system. Waste water usually is clean enough to filter and dispose of down a drain. The garnet abrasive is a nontoxic material that can be recycled for repeated use; otherwise, it can usually be disposed in a landfill. Water jets also produce fewer airborne dust particles, smoke, fumes, and contaminants,[30] reducing operator exposure to hazardous materials.[31] Meatcutting using waterjet technology eliminates the risk of cross contamination since there is no contact medium (namely, a blade) between different animals in the slaughterhouse.
Versatility
A water jet cutting a metal tool
Because the nature of the cutting stream can be easily modified the water jet can be used in nearly every industry; there are many different materials that the water jet can cut. Some of them have unique characteristics that require special attention when cutting. Materials commonly cut with a water jet include rubber, foam, plastics, leather, composites, stone, tile, metals, food, paper and much more. Materials that cannot be cut with a water jet are tempered glass, diamonds and certain ceramics.[31] Water is capable of cutting materials over eighteen inches (45 cm) thick. The penetrating power of these tools has led to the exploration of their use as anti-tank weapons but, due to their short range and the advent of composite armour, research was discontinued.[citation needed]
Availability
Commercial water jet cutting systems are available from manufacturers all over the world, in a range of sizes, and with water pumps capable of a range of pressures. Typical water jet cutting machines have a working envelope as small as a few square feet, or up to hundreds of square feet. Ultra-high pressure water pumps are available from as low as 40,000 psi (276 MPa) up to 100,000 psi (689 MPa).[30]
Process
There are six main process characteristics to water jet cutting:
1. Uses a high velocity stream of abrasive particles suspended in a stream of Ultra High Pressure Water (30,000–90,000 psi) which is produced by a water jet intensifier pump. 2. Is used for machining a large array of materials, including heat-sensitive, delicate or very hard materials. 3. Produces no heat damage to workpiece surface or edges. 4. Nozzles are typically made of sintered boride. 5. Produces a taper of less than 1 degree on most cuts, which can be reduced or eliminated entirely by slowing down the cut process. 6. Distance of nozzle from workpiece affects the size of the kerf and the removal rate of material. Typical distance is .125″ (3.175 mm).
Temperature is not as much of a factor.
Multi-axis cutting
Main article: Multiaxis machining
A 5-Axis Waterjet Cutting Head
A 5-Axis Waterjet Part
Operation
The cutter is commonly connected to a high-pressure water pump where the water is then ejected from the nozzle, cutting through the material by spraying it with the jet of high-speed water. Additives in the form of suspended grit or other abrasives, such as garnet and aluminium oxide, can assist in this process.
is no "heat-affected zone" (HAZ). Minimizing the effects of heat allows metals to be cut without harming or changing intrinsic properties.
Water jet cutters are also capable of producing intricate cuts in material. With specialized software and 3-D machining heads, complex shapes can be produced.[30]
The kerf, or width, of the cut can be adjusted by swapping parts in the nozzle, as well as changing the type and size of abrasive.
Water jets are capable of attaining accuracies down to 0.005″ (0.13 mm) and repeatabilities down to 0.001″ (0.025 mm).[30]
water jet cutting can reduce the amount of scrap material produced, by allowing uncut parts to be nested more closely together than traditional cutting methods.
Water jets use approximately one half to one gallon per minute (depending on the cutting head's orifice size), and the water can be recycled using a closed-loop system. Waste water usually is clean enough to filter and dispose of down a drain. The garnet abrasive is a nontoxic material that can be recycled for repeated use; otherwise, it can usually be disposed in a landfill. Water jets also produce fewer airborne dust particles, smoke, fumes, and contaminants,[30] reducing operator exposure to hazardous materials.[31] Meatcutting using waterjet technology eliminates the risk of cross contamination since there is no contact medium (namely, a blade) between different animals in the slaughterhouse.
Versatility
A water jet cutting a metal tool
Because the nature of the cutting stream can be easily modified the water jet can be used in nearly every industry; there are many different materials that the water jet can cut. Some of them have unique characteristics that require special attention when cutting. Materials commonly cut with a water jet include rubber, foam, plastics, leather, composites, stone, tile, metals, food, paper and much more. Materials that cannot be cut with a water jet are tempered glass, diamonds and certain ceramics.[31] Water is capable of cutting materials over eighteen inches (45 cm) thick. The penetrating power of these tools has led to the exploration of their use as anti-tank weapons but, due to their short range and the advent of composite armour, research was discontinued.[citation needed]
Availability
Commercial water jet cutting systems are available from manufacturers all over the world, in a range of sizes, and with water pumps capable of a range of pressures. Typical water jet cutting machines have a working envelope as small as a few square feet, or up to hundreds of square feet. Ultra-high pressure water pumps are available from as low as 40,000 psi (276 MPa) up to 100,000 psi (689 MPa).[30]
Process
There are six main process characteristics to water jet cutting:
1. Uses a high velocity stream of abrasive particles suspended in a stream of Ultra High Pressure Water (30,000–90,000 psi) which is produced by a water jet intensifier pump. 2. Is used for machining a large array of materials, including heat-sensitive, delicate or very hard materials. 3. Produces no heat damage to workpiece surface or edges. 4. Nozzles are typically made of sintered boride. 5. Produces a taper of less than 1 degree on most cuts, which can be reduced or eliminated entirely by slowing down the cut process. 6. Distance of nozzle from workpiece affects the size of the kerf and the removal rate of material. Typical distance is .125″ (3.175 mm).
Temperature is not as much of a factor.
Multi-axis cutting
Main article: Multiaxis machining
A 5-Axis Waterjet Cutting Head
A 5-Axis Waterjet Part
