Product category:
CNC water jet cutting and profiling machines
News Release from: KMT Waterjet Systems | Subject: Applications for the water-jet cutting process
Edited by the Manufacturingtalk Editorial
Team on 02 May 2006
Applications for the water-jet cutting
process
High-speed prototyping and flexible, just-in-time production are well suited to water-jet alongside new applications including cleaning, recycling and decommissioning.
Flexible water-jet cutting technology can be used in practically all sectors of industry - an article by Peter Longman, Area Manager, KMT Waterjet Systems The aerospace, building and construction, mechanical engineering, glass industry, wood, textiles and paper manufacturing sectors are all taking advantage of this versatile process
This article was originally published on Manufacturingtalk on 6 May 2008 at 8.00am (UK)
Related stories
Waterjet cutting intensifier saves service costs
Waterjet cutting intensifier is offered in models offering pressure up to 4150 bar and run one 0.35mm or two 0.25mm water orifices at 4100 bar for greater flow.
Ensuring high-quality abrasive waterjet cutting
An abrasive metering system ensures a consistent supply of abrasive to the cutting head to benefit from consistent high quality abrasive waterjet cutting.
In addition, the automotive and its supplier industries, as well as the electrical, electronic and food processing and defence industries have all emerged as markets for some of the more novel applications of water-jet.
High-speed prototyping and flexible, just-in-time production are well suited to water-jet whilst new applications including cleaning, recycling and decommissioning.
Unlike traditional thermal cutting methods, water-jet cutting technology has major advantages in terms of its high level of cost-effectiveness and flexibility.
Further reading
Intensifier boosts water jet cutting systems
A 30HP intensifier is an affordable, self-contained readily connectable unit that provides cutting pressure of up to 3.600 bar/ 52.000 lb/in2 for single- or multiple-head water jet machines.
HP intensifier halves water jet running costs
A UK subcontract materials water jet cutting and profiling firm said that one of the major advantages of a high-pressure intensifier is that it virtually halves the running costs.
Jet cutting water supplied at constant pressure
A compact non-transparent high-quality plastics tank and pump has a capacity of 1000 litres to ensure that there is always sufficient water available for all water jet cutting applications.
The most diverse materials can be quickly and precisely worked using a high-pressure jet of water.
Material thicknesses of 150 mm or more present no difficulties for this cutting processes.
The water-jet achieves optimum cut-edge qualities on both simple and extremely complex contours.
Water- jet cutting falls into general 2D and 3D applications.
2D include the cutting of sheet metal such as: stainless steel, carbon steel, high-alloy nickel steels, aluminium, titanium and copper.
Construction materials include decorative stone, marble, granite, tiles, plasterboard, glass and mineral wool.
Glass covers: laminated glass, safety glass, and bulletproof glass.
Foodstuffs can range from baked goods to deep-frozen products and fish.
Paper, cardboard, corrugated cardboard, printing papers together with miscellaneous materials such as: plywood, leather, textiles, composites, rubber, plastics, sealing materials and foams are also typical 2D applications.
3D and robot applications cover abrasive cutting of titanium, aluminium and stainless steel motor-vehicle components; turbine blades, decorative stone or marble.
Pure water cutting can be used for motor-vehicle components such as carpets, door-trims, fenders, dashboards, instrument panels, rear shelves.
The essential benefits of the water-jet cutting system are the fact that there are no heat-affected zones, no thermal hardening and no material stresses.
From a health and safety point of view there are also no gases and no production of dust or fumes.
Production benefits include the fact that there is no need to sharpen tools whilst high cutting speeds.
high cutting accuracy and high surface quality can be achieved.
Secondary operations such as deburring can be omitted and re-working becomes unnecessary.
Burr-free cut edges, a narrow cutting gap and low tangential forces exerted on the component also provide user benefits.
Waterjet can be used for both cleaning and removing layers of materials from the surface of products.
KMT's Streamline pump range can provide high pressure to the Rotojet nozzle so that cleaning can be undertaken in an environmentally friendly way without any gases.
The base material's integrity is not affected and the process is therefore ideally suited to applications such as jet engine turbine blade decontamination.
As part of the restoration and repair of gas turbine jet engine components undertaken by Wood Group Component Repair, coatings need to be stripped from turbine components prior to re-application.
In order to refine the coating removal process, Wood Group is currently carrying out development work using a KMT waterjet system.
This significantly speeds up the process without affecting the base material.
Hundreds of different coatings are applied to the turbine component parts by plasma arc deposition - mainly on to casings and seal areas where the ceramic or other coating is intended to wear in preference to the mating part.
At present the plasma sprayed coatings are removed by conventional machining, acid bath and grit blasting.
This is a very time consuming operation and some of the base material is removed during the operation.
These problems are eliminated by the waterjet process comprising of a Streamline SL IV 50Hp pump that produces 3,800bar (55,000psi) working pressure.
It utilises a Rotojet rotating cleaning nozzle with a fully adjustable rotational speed of up to 400 rpm.
This process safely removes the plasma layer and nickel-based bonding coat without putting the substrate at risk, at the same time eliminating any danger of contamination.
CNC controlled, the 5-axis machine is able to cope with components over 1 metre in diameter, the operator only being required to select the relevant programme for the component.
The Rotojet head then follows a predetermined path to remove effectively and safely all the old coating.
Jetting technology is also helping to solve some of the world's environment problems in cleaning and recycling applications as in the decommissioning of nuclear facilities and military hardware.
The successful removal of offshore structures needs effective subsea technology.
Amongst the most challenging tasks is the cutting of multi-strong casings, which can be 30 inches diameter and need to be delivered below the sea-bed.
Explosives can cause damage and have environmental disadvantages whilst high powerful abrasive water jetting systems have proven an effective and flexible means of decommissioning.
Portable, abrasive waterjet cutting systems can also help deal with unexploded ordnance.
Disposal traditionally involves cutting at close quarters with tools that cause vibration and this is a high risk activity.
Abrasive waterjet represents a safer alternative.
It can be controlled remotely and only requires a 'single approach' to be made to the ordnance to achieve core access.
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