As reported by The Fabricator in their article “Achieve peak waterjet performance by optimizing components,” successful fabrication shops maximize the productivity of their waterjet machines by optimizing the system and its components. Peak performance of the waterjet system enhances cutting rates and profitability.
A waterjet system consists of an ultrahigh-pressure pump, a CNC machine, and one or more cutting heads. The setup and optimization of these components determine the system’s performance. Waterjet cutting pumps vary from 15 to 200 horsepower, delivering pressures of 40,000 to over 60,000 PSI. Small pumps typically feed single cutting heads with small jets, while larger pumps can handle multiple heads with larger jets.
The pump delivers high-pressure water to the on/off valve on the CNC machine. The high-pressure water from the valve enters the cutting head, where the orifice (0.007 to 0.018 inch ID) creates the jet. This high-velocity jet creates a vacuum in the mixing region of the head, drawing garnet abrasive into the cutting head. The abrasive-laden jet then exits the nozzle (0.02 to 0.045 inch ID) as a high-velocity stream of water, abrasive, and air.
Optimizing parameters like orifice diameter, nozzle ID, abrasive flow, and pump pressure is crucial for maximizing output. The machinability of the material, material thickness, and desired cut edge finish also influence the cut speed. Balancing these factors allows operators to achieve the required tolerance and edge finish while maintaining high cut rates and parts output.
The cut edge has two regions: a smooth, sandblasted appearance at the top and a striated, wavy bottom. High-quality cuts (quality 5) have a smooth region extending through the cut edge, while lower-quality cuts (quality 1 or 2) are striated throughout. Operators can improve cut edge quality by adjusting the feed rate, balancing the need for a good edge finish with the need for high cutting speed.
Increasing pump pressure is an easy way to cut faster. Higher pressure boosts jet velocity and water flow through the orifice, but it also shortens the wear life of high-pressure components, leading to more frequent maintenance.
Excellence is demonstrated in optimizing waterjet cutting systems to ensure peak performance. Expertise in managing operating parameters and cutting components results in efficient and high-quality cuts. By leveraging advanced waterjet technologies, maximum productivity and profitability are achieved for fabrication shops.
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Article with all rights reserved, courtesy of thefabricator.com