This article will delve into the mechanics of waterjet cutting and explore why garnet stands out from other abrasives.

Waterjet cutting employs a high-pressure stream of water, often combined with an abrasive substance, to cut through a wide range of materials.

Garnet, with its exceptional hardness and optimal grain shape, has become the preferred abrasive for this process, offering unmatched cutting capabilities.

Why Use Garnet in Waterjet Cutting?

In waterjet cutting, the choice of abrasive determines the efficiency, precision, and cost-effectiveness of the cutting process. Garnet, with its unique physical and chemical properties, stands out as the premier choice for this application.

Its significance in waterjet cutting cannot be overstated, offering a harmonious blend of hardness, density, and recyclability that other abrasives struggle to match.

What are the Physical and Chemical Properties of Garnet?

Garnet, particularly almandine garnet, boasts a hardness that is unrivaled among natural abrasives, ranking between 7.5 and 8.5 on the Mohs scale. This exceptional hardness enables it to cut through tough materials like stainless steel, glass, and composite materials with ease.

Moreover, garnet’s angular particle shape enhances its cutting ability, allowing for precise and clean cuts with minimal kerf.

The chemical stability of garnet ensures that it does not react adversely with the materials it cuts or the water stream used in the cutting process.

This stability, coupled with garnet’s high specific density, allows for quicker settling of particles, reducing wear on the waterjet cutting machine’s components and extending nozzle life.

What are Comparative Advantages of Garnet Over Other Abrasives

Garnet offers several advantages over traditional abrasives such as silicon carbide, slag, and even sand.

Its superior hardness and cutting speed allow for faster processing times, while its particle shape and size consistency contribute to exceptional edge quality and surface finish.

From an environmental perspective, garnet is safer to handle and generates less dust during cutting, minimizing health risks associated with airborne particles.

The recyclability of garnet is a further advantage, offering significant cost savings and environmental benefits.

Unlike one-time use abrasives, garnet can be recycled multiple times without a significant loss in performance, reducing both the material cost and the impact on landfill disposal.

How to Choose the Right Garnet Abrasive?

Selecting the appropriate garnet abrasive for waterjet cutting involves understanding the specific requirements of the cutting application, including the material to be cut, the desired cutting speed, and the level of precision required.

Understanding Mesh Grades and What They Signify

Mesh size is a critical factor in selecting garnet abrasive, as it directly affects the cutting precision and efficiency.

The term “mesh size” refers to the number of holes in a screen per inch, with higher numbers indicating finer particles. For waterjet cutting, garnet abrasives typically range from 50 mesh for coarse cutting to 120 mesh for fine precision cutting.

Smaller mesh sizes (higher numbers) produce finer abrasives, ideal for detailed work on delicate materials, achieving a superior surface finish with minimal material waste.

Conversely, larger mesh sizes (lower numbers) are better suited for cutting through thicker or harder materials, offering faster cutting speeds but at the potential cost of precision.

Attributes to Consider

• Hardness: Essential for cutting through tough materials.
• Density: Affects the force at which garnet particles hit the cutting surface.
• Toughness: Determines the abrasive’s resistance to shattering on impact.
• Particle Shape: Influences the cutting action and the quality of the cut edge.
• Recyclability and environmental impact: A key consideration for operational cost efficiency and sustainablity.

Alluvial vs. Rock Garnet: Which is Better?

Alluvial garnet, found in riverbeds, is naturally rounded and typically has a higher purity than rock garnet.

This makes it ideal for applications requiring a smooth surface finish.

Rock garnet, mined from hard rock deposits, is more angular and is preferred for its aggressive cutting action and durability.

The choice between the two depends on the specific requirements of the cutting application, with alluvial garnet being preferable for most applications, and rock garnet being used for particular and tougher, more demanding cuts.

However, rock garnet is much harsher on consumables like focusing tubes, abrasive feeders and abrasive hose.

Here are a few tips  :

• For thick, tough materials like stainless steel or titanium: Choose a coarser, rock garnet.
• For precise cuts on delicate materials like glass or ceramics: Opt for a finer, alluvial garnet.

The Importance of Garnet Purity and Quality

The effectiveness of garnet in waterjet cutting is also heavily influenced by its purity and quality.

Impurities in the garnet, such as dust, clay, or other minerals, can significantly impair the cutting process, leading to reduced cutting speed, poorer edge quality, and increased wear on the waterjet machine.

How to Assess Garnet Quality?

The best way is to half fill a small plastic water bottle with abrasive, add some water and shake it up. If the water turns dirty it has impurities such as dust, clay, or other minerals. If the water stays mainly clear its of good quality.

What are the Environmental and Economic Benefits of Using Garnet?

Garnet, beyond its effectiveness as an abrasive, shines through its eco-friendliness, safety, cost implications, and especially its recyclability, creating a harmonious balance between environmental sustainability and economic efficiency.

Eco-friendliness and Safety

Garnet’s environmental credentials are impeccable. Unlike some other abrasives that contain toxic materials or lead to hazardous dust, garnet is chemically inert and free of silica, making it safe for operators and the environment alike.

ts use significantly reduces the generation of airborne particles, thus lowering the risk of respiratory issues among workers and minimizing the impact on surrounding ecosystems.

This safety aspect, coupled with its natural abundance, positions garnet as a preferred choice for businesses aiming to maintain high environmental standards.

Cost Implications: Initial Cost vs. Long-term Savings

While the initial purchase price of garnet may be higher than some alternatives, its longevity and recyclability offer substantial long-term savings.

Garnet’s exceptional hardness and durability mean that it can be reused multiple times in waterjet cutting processes without losing its effectiveness, reducing the need for frequent replacements.

Moreover, the efficiency of garnet in achieving precise and clean cuts reduces material wastage, further enhancing its cost-effectiveness. This attribute makes garnet not only an environmentally sound choice but also an economically wise investment for industries.

The Recyclability of Garnet and Its Benefits

One of the standout features of garnet is its recyclability, which has a dual benefit: it considerably lessens environmental impact and lowers the cost per use.

Recycled garnet particles retain their cutting capabilities, which means they can be reused in several cutting operations before disposal. This recyclability reduces the demand for mining and processing new garnet, thereby conserving resources and reducing the carbon footprint associated with production and transportation.

Furthermore, the ability to recycle garnet means less waste heads to landfills, making it an exemplary model of sustainable industry practices.

What are Application Areas of Garnet in Waterjet Cutting?

Garnet’s versatility makes it suitable for a wide array of materials, marking it as the abrasive of choice for diverse waterjet cutting applications. Its hardness, cutting speed, and the quality of the finish it provides enable precision cutting across various industries.

Materials Suitable for Cutting with Garnet-Abrasive Waterjets

The materials below highlight the broad applicability of garnet in waterjet cutting, capable of delivering high precision and minimal edge distortion across different textures and densities.

• Metals: Stainless steel, aluminum, titanium, and copper
• Stone and Tiles: Marble, granite, and ceramics
• Glass: Including toughened safety glass and decorative glass panels
• Composites: Carbon fiber and fiberglass
• Plastics and Rubber: For intricate shapes and sizes

Industry-specific Applications

• Aerospace: Fabricating components from titanium and aluminum alloys
• Manufacturing: Cutting custom parts for machinery, vehicles, and equipment
• Construction and Architecture: Shaping stone for buildings and creating intricate tile designs
• Art and Design: Crafting detailed artworks and decorative elements from glass and metals
• Shipbuilding: Cutting steel plates and parts for marine vessels

What are Technical Aspects of Waterjet Cutting with Garnet?

Understanding the technical nuances of operating waterjet cutting machines with garnet is essential for achieving optimal performance and safety.

Let’s start with the machine setup.

Waterjet Cutting Machine Setup for Garnet

Setting up a waterjet cutting machine involves configuring it to utilize garnet effectively. This setup is crucial for ensuring that the waterjet can cut through various materials with high precision and efficiency.

The key factors include ensuring the garnet is of high quality and the right mesh size, adjusting the water pressure to the appropriate level, and calibrating the machine’s cutting speed.

Safety Precautions When Handling Garnet and Operating Waterjet Cutters

Safety is paramount when handling garnet and operating waterjet cutters.

It’s essential to wear protective gear, including gloves and goggles, to prevent direct contact with the garnet, which can be abrasive.

Additionally, ensuring the waterjet cutting machine is properly maintained and operated can prevent accidents and improve the machine’s lifespan.

Maintenance and Troubleshooting

Regular maintenance tasks are essential for the smooth operation of waterjet cutting machines. A maintenance checklist includes:

• Checking the cutting head for worn orifice or focusing tube
• Checking the garnet feed to ensure consistent flow and to prevent blockages
• Monitoring water pressure and quality for optimal performance

Common troubleshooting tips address issues like uneven cutting, slow cutting speed, and machine downtime. Regularly consulting the manufacturer’s guidelines can prevent these problems and extend the machine’s life.

Conclusion

Garnet with its unique combination of hardness, durability, and recyclability, stands as a cornerstone in the waterjet cutting technology landscape. The insights gathered throughout this discussion not only highlight the technical and operational excellence achievable with garnet but also underscore its environmental and economic advantages.

Frequently Asked Questions (FAQs)

1. Can garnet be reused in waterjet cutting?

Yes, garnet can be reused in waterjet cutting operations. Its exceptional hardness and toughness allow it to maintain its cutting capabilities over multiple uses. However, it does lose some of its sharp edges, and some are smashed into finer partials that are discarded. Typically, recycled garnet is mixed with new garnet.

2. How does waterjet cutting with garnet compare to laser cutting?

Waterjet cutting with garnet offers distinct advantages over laser cutting, particularly in terms of versatility and material integrity. Waterjet cutting can process a wider variety of materials, including metals, stones, and composites, without inducing thermal stress or altering the material’s inherent properties. While laser cutting is renowned for its precision and speed in certain applications, waterjet cutting excels in its ability to cut thicker materials and provide a smooth, burr-free finish.

3. What are the limitations of waterjet cutting with garnet?

While waterjet cutting with garnet is highly versatile and efficient, it does have limitations. The process can be slower and more costly than other cutting methods when working with very thick materials or requiring extremely high precision. Additionally, the initial setup and ongoing maintenance of waterjet cutting machines necessitate a significant investment in both time and resources.

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In the article below, we will discuss how important water quality is in waterjet cutting, ensuring operational excellence, and extending machine lifespan.

Is Water Quality Important in the Waterjet Cutting Process?

Yes, water quality is of utmost importance in the waterjet cutting process. The efficacy of waterjet cutting—a technique that relies on high-pressure water possibly mixed with an abrasive to slice through materials—relies significantly on the condition of the water used.

Impure water can lead to a slew of issues, including clogged nozzles and diminished cutting precision, thereby affecting the overall productivity and operational costs.

Ensuring the water used is of good quality is not just beneficial but crucial for maintaining the cutting system’s efficiency and longevity.

Why Water Quality Is Very Important For Water-jet Cutting?

Water quality impacts several critical aspects of the cutting process, influencing not just the outcome but also the durability and reliability of the cutting system.

Here’s why water quality merits careful consideration:

Process Water

Process water, or the water directly used in the cutting stream, must meet specific purity standards. Total dissolved solids (TDS) and impurities within the water can affect the jet’s velocity and consistency, leading to subpar cutting performance.

Ensuring low TDS levels and employing water treatment methods like reverse osmosis (RO) or deionization (DI) can enhance cutting accuracy and reduce wear on the machine components.

Cooling Water

Cooling water plays a vital role in regulating the temperature of key components such as the pump and the nozzle. The quality of cooling water, particularly its mineral content and pH level, can affect the heat exchange efficiency and lead to scale buildup, impacting the waterjet system’s cooling efficiency.

Employing water softening techniques and monitoring the cooling water’s quality can prevent overheating and prolong the system’s service life.

How does water quality impact a waterjet cutting process’s overall efficiency and productivity?

Water quality impacts several critical aspects of the cutting process, influencing not just the outcome but also the durability and reliability of the cutting system.

In this section, you’ll discover how water quality affects cutting performance, machine lifespan, surface finish, precision, system reliability, operating costs, and environmental impact.

Cutting Performance

The cutting performance of a waterjet system is fundamentally influenced by the quality of water. High-quality water, characterized by low total dissolved solids (TDS) and minimal impurities, ensures a consistent and powerful waterjet stream.

This stream is capable of cutting materials with precision and minimal kerf, reducing waste and improving cut quality. Conversely, water with high TDS or impurities can lead to inconsistent stream pressure and diminished cutting accuracy.

What are the potential effects of poor water quality on the cutting performance of a waterjet system?

Poor water quality can result in decreased cutting speed and efficiency, requiring more passes to achieve the desired cut. This not only slows down production but also increases wear on the machine’s components, reducing the system’s overall productivity.

The lifespan

The lifespan of a waterjet machine is closely tied to the quality of water it utilizes. Water with high mineral content or other impurities can lead to accelerated wear and tear on the high-pressure components, including the pump, nozzles, and tubing.

Effective water quality analysis and filtration can significantly extend the service life of these components.

Water laden with high levels of solids and minerals can cause clogging and increased wear on the waterjet’s intricate components.

Surface Finish and Precision

The surface finish and precision of the cuts made by a waterjet cutter are directly influenced by water quality.

Pure, soft water allows for a smoother cut, minimizing the occurrence of striations and improving the overall finish.

Optimal water quality ensures that the waterjet stream remains steady and powerful, enabling it to cut materials with high precision and produce finishes that meet stringent quality standards.

System Reliability

The reliability and uptime of a waterjet cutting system are significantly affected by water quality. High-quality, clean water reduces the risk of blockages and wear, ensuring the machine operates reliably over longer periods.

Using water that meets the system’s quality requirements minimizes unexpected downtimes caused by maintenance issues, thereby enhancing the machine’s reliability and operational efficiency.

Operating Costs

Water quality directly impacts the operating costs associated with running a waterjet system. Poor quality water increases the frequency of waterjet maintenance and the need for replacement parts.

Increased wear and maintenance needs due to poor water quality can lead to higher operating costs, including more frequent downtime and greater expenditure on parts and labor.

Environmental impact

The environmental considerations associated with water quality in waterjet cutting encompass both the source of the water and its treatment after use.

Ensuring water quality not only benefits the cutting process but also reduces the environmental impact by minimizing waste and facilitating the recycling of water used in the cutting process.

TDS Levels

 The industry standard for Total Dissolved Solids (TDS) in waterjet cutting systems generally recommends a TDS level of less than 100 parts per million (ppm) for optimal performance. This low level of TDS helps in minimizing wear on the machine’s components , such as the high-pressure pump and the cutting head, thereby extending their operational life.

pH Levels

The pH level of water used in waterjet cutting should ideally be neutral, ranging between 6.5 and 8.5. This range is crucial to prevent corrosion of machine components and ensure the stability of the waterjet stream. Water outside this pH range should be treated to adjust its acidity or alkalinity.

Silica Content

Silica content in the water should be kept to a minimum, ideally below 15 parts per million. High silica levels can lead to the formation of scale and sediment, which can clog the machine’s fine orifices and tubes, reducing efficiency and potentially causing downtime for maintenance.

Water Hardness

Softened water, typically with hardness levels below 17 parts per million (or 1 grain per gallon), is recommended to prevent scale buildup in the waterjet system. Scale can impede water flow and reduce the efficiency of heat exchangers and pumps.

Filtration Requirements

 Effective filtration systems are crucial for removing particulate matter from the water. Filters with a rating of 1 micron or less are recommended for removing fine particles that could clog the nozzle or erode machine components.

Regular Monitoring and Testing

Regular water quality testing is advised to ensure that the water remains within the specified standards for TDS, pH levels, silica content, and hardness. This proactive approach can help in identifying potential water quality issues before they affect the cutting process or machine health.

Treatment Methods

Depending on the initial quality of the water source, treatment methods such as reverse osmosis, deionization, water softening, or chemical adjustment may be necessary to meet these standards. The choice of treatment method depends on the specific contaminants present in the water supply.

What are the potential risks associated with poor water quality?

As already explained, poor water quality not only hampers the cutting efficiency but also imposes several risks on the machinery and the overall operational integrity.

Understanding these six major risks is crucial for maintaining a high-performance waterjet cutting system.

• Nozzle Blockages: Water replete with sediments and particulate matter can lead to frequent nozzle blockages. This not only disrupts the cutting process but also necessitates regular maintenance, increasing operational downtime.
• Reduced Cutting Performance: Impurities and high levels of total dissolved solids (TDS) in water can diminish the waterjet’s power, leading to reduced cutting performance. This inefficiency can extend cutting times and negatively affect the quality of the finished product.
• Nozzle Wear and Damage: Water containing abrasive particles or hard minerals significantly accelerates nozzle wear. Over time, this heightened wear can degrade the nozzle, impairing cutting accuracy and necessitating costly replacements and increased maintenance efforts.
• Equipment Corrosion: Water with a high acidity level (low pH) or containing corrosive chemicals can lead to the corrosion of critical waterjet components. This degradation not only shortens the lifespan of the machinery but can also lead to catastrophic failures if not addressed promptly.
• Surface Quality Issues: The quality of cuts can be adversely affected by poor water quality. Issues such as uneven surfaces, increased kerf width, and poor edge quality are common, leading to dissatisfaction with the final product and potentially increasing waste.
• Inefficient Water Consumption: Poor water quality can result in the need for more frequent water changes and increased consumption. This inefficiency not only affects operational costs but can also impact the environment due to increased water usage and waste.

What are the best practices or recommendations for maintaining optimal water quality in waterjet cutting?

We have prepared a list of nine fundamental practices and recommendations for maintaining optimal water quality:

• Regular Water Testing: It’s essential to conduct regular water testing to assess various parameters such as pH levels, mineral content, conductivity, and bacterial presence. This proactive approach allows for timely adjustments to water treatment processes.
• Maintain the Filtration System: Adhering to the manufacturer’s recommendations for the filtration system maintenance—including regular inspection, cleaning, and filter replacement—is crucial. Proper filtration prevents particulates from entering the cutting system, safeguarding against blockages and wear.
• Water Treatment Equipment Maintenance: Regularly maintain and inspect water treatment equipment to ensure its effective operation. Systems such as reverse osmosis, deionizers, and water softeners play a crucial role in maintaining water quality.
• Clean Water Storage: Ensure that water storage tanks are clean and free from contaminants. Regular cleaning prevents the growth of bacteria and algae, which can degrade water quality.
• Implement a Preventive Maintenance Schedule: Establishing a routine for inspecting and cleaning water lines, nozzles, and components helps in identifying and addressing potential issues before they escalate.
• Train Operators and Maintenance Personnel: Educating staff on the importance of water quality and proper maintenance procedures ensures that everyone is equipped to identify and address water quality issues promptly.
• Develop Documented Procedures: Having a set of documented procedures for water quality monitoring, maintenance, and troubleshooting provides a clear guideline for staff, ensuring consistency in practices.
• Conduct Regular Inspections: Routine inspections of the waterjet cutting system—including the water lines, nozzles, pump, and associated components—are essential. Look for signs of corrosion, leaks, or degradation that could impact water quality or system performance.
• Maintain Accurate Records: Keeping detailed records of water quality test results, maintenance activities, and corrective actions taken is vital for tracking the system’s health and making informed decisions about water treatment needs.

Conclusion

Maintaining optimal water quality in waterjet cutting systems is not just about following a set of guidelines—it’s about creating a culture of diligence and responsibility. By adhering to the best practices outlined above, operators can ensure their waterjet cutting operations are not only efficient and precise but also sustainable and cost-effective. The journey towards optimal water quality management is ongoing, requiring constant vigilance, education, and adaptation to new challenges and technologies.

The post What is the Importance of Water Quality in Waterjet Cutting? appeared first on TechniWaterjet.

What Is Waterjet Cutting?

At its core, waterjet cutting is a force of innovation in the manufacturing landscape. This process utilizes a high-pressure stream of water, often mixed with abrasive particles, to slice through a myriad of materials with unmatched precision. From metals and stones to composites and plastics, waterjet cutting does it all, without the heat stress that plagues traditional cutting methods.

What Are the Common Problems in Waterjet Cutting?

Waterjet cutting, a versatile and efficient method for slicing through materials with a high-pressure stream of water, is integral to industries ranging from aerospace to manufacturing. This technology relies on the precise application of water, sometimes mixed with abrasives, to cut a variety of materials, including metal, stone, and glass. However, like any sophisticated machinery, waterjet systems encounter their share of challenges. Understanding these problems, their causes, and solutions ensures the longevity and efficiency of waterjet cutters, aligning with the vital role of water in supporting life and processes.

Common Problems in Waterjet Cutting:

• Nozzle Wear: The intense conditions inside the cutting nozzle can lead to its rapid wear, affecting precision and efficiency.
• Abrasive Feed Issues: Incorrect abrasive flow can compromise cutting speed and quality.
• Clogging of the Cutting Head: Obstructions in the cutting head disrupt water flow, leading to subpar cuts.
• Water Quality Problems: Poor water quality can damage components and affect operation.

Each of these issues not only impacts the cutting quality but also the reliability and maintenance costs of waterjet systems. Let’s delve into each problem, exploring their causes and offering troubleshooting tips for effective resolution.

Nozzle Wear

The nozzle, or orifice, is where water accelerates to high speeds, creating the cutting stream. Over time, this intense activity leads to wear, primarily due to the abrasive particles used in cutting. This wear degrades the precision of the water jet, resulting in uneven cuts or reduced cutting ability.

Solutions:

• Regular inspection and replacement of worn nozzles.
• Use of high-quality nozzles designed for longevity.
• Calibration of the abrasive feed to minimize unnecessary wear.

Abrasive Feed Issues

Abrasives such as garnet are mixed with water to enhance cutting power. However, inconsistent or incorrect abrasive flow can lead to inefficient cutting processes, affecting both speed and quality.

Solutions:

• Ensure the abrasive hopper is filled and functioning properly.
• Regularly check and adjust the abrasive feed rate according to material being cut.
• Implement a monitoring system to alert operators to feed issues.

Clogging of the Cutting Head

Clogging usually occurs when particles or debris obstruct the water stream, leading to diminished cutting performance or even stopping the cutting process entirely.

Solutions:

• Regular cleaning and maintenance of the cutting head.
• Use of a water filtration system to minimize the introduction of debris.
• Inspection of the abrasive for any potential clogging materials before use.

Water Quality Problems

Water quality plays a critical role in the operation of waterjet systems. Hard water can lead to scale buildup, while contaminated water can cause corrosion and wear on various components.

Solutions:

• Use of a water softener to treat hard water.
• Regular testing and treatment of water to ensure it meets machine specifications.
• Installation of filters and regular replacement to remove contaminants.

Leaks in the Waterjet System

Leakage in waterjet systems can significantly impact their performance and safety. Identifying the source of leaks is crucial for timely maintenance and repair. Damage to high-pressure water seals and hoops often leads to water leakage from the intensifier. A drip of water every few strokes suggests that seals are nearing their end and should be replaced promptly. More frequent drips indicate an urgent need for seal replacement.

Common Causes and Solutions for Water Leaks:

• Overstroking and Hydraulic Pressure Failure: These issues can lead to leaks and are often signs of more significant system malfunctions. Regular maintenance checks and prompt repairs are essential.
• Loose Fittings or Damaged Seats: Ensure all fittings are tight and seats are not damaged to prevent leaks. Regular inspections can identify these issues early.
• Worn Parts: Replace worn parts immediately to avoid leaks that can damage nearby components.
• High-Pressure Seal Failure: If warm or hot water leaks from various system parts, it might indicate a failure in high-pressure seals. Replacing these seals is critical to prevent further leakage.

How Can Water Leaks Be Detected?

Detecting water leaks in a waterjet system involves regular inspection and monitoring for signs of moisture or unexpected drops in water pressure. Key indicators include:

• Visible Drips or Puddles: Regularly inspect the machine for any signs of water accumulation.
• Changes in Water Pressure: A sudden drop in water pressure gauges readings can indicate a leak.
• Unusual Noises: Listen for any sounds that might indicate leaking or spraying water within the system.

Inconsistent Water Pressure

The Problem: Inconsistent water pressure is a prevalent issue in waterjet cutting, leading to uneven cuts and compromised precision. This variability can be attributed to several factors, including pump malfunctions, clogged nozzles, or issues within the water supply system.

Solutions:

• Regular maintenance checks on the waterjet pump and nozzles to ensure they are in optimal condition.
• Monitoring the water supply for any signs of disruption and installing a prefilter water pressure gauge to detect fluctuations early.
• Adjusting the pressure control knob as needed and ensuring the pressure control circuit is functioning correctly to maintain stable water pressure.

Material Handling Difficulties

The Problem: Handling and securing materials for cutting can pose significant challenges, especially when dealing with intricate designs or delicate materials. These difficulties can lead to material wastage, increased operational costs, and reduced cutting precision.

Solutions:

• Implementing advanced material handling systems that can accurately position and secure materials throughout the cutting process.
• Using software solutions to plan and optimize cutting paths, minimizing waste and improving material utilization.
• Training operators on best practices for material handling, including the use of appropriate jigs and fixtures to enhance stability and cutting accuracy.

Hydraulic Fluid Pressure Failure

The Problem: Failure to build adequate hydraulic pressure, which directly impacts water pressure, is another significant challenge. This issue can stem from a malfunctioning pump, incorrect settings on the pressure control knob, or problems within the hydraulic system, such as overheated hydraulic fluid or opening relief valves.

Solutions:

• Ensure the pressure control knob is correctly adjusted and that the pump compensator is effectively isolated from the pressure control circuit to verify its ability to raise pump pressure.
• Regularly inspect and measure the temperature of hydraulic relief valves. An increase in temperature compared to surrounding components may indicate that the valve is opening and needs attention.
• Consult with a service technician to diagnose and address more complex issues within the hydraulic system, such as replacing or repairing faulty components like the relief valve, pump, or hydraulic fluid overheating solutions.

Overstroking

Overstroking in waterjet cutting systems is a phenomenon that can cause significant disruptions in operations. It occurs when the hydraulic piston of the intensifier moves faster than the pump can support, either in one or both directions, potentially triggering an alarm. This issue is not just a matter of mechanical overexertion; it reflects deeper problems within the waterjet’s hydraulic or pressure control systems.

The cause of overstroking can be multifaceted, ranging from water leakage, improper pressure settings, to wear and tear of water seals or the orifice. The intensifier, designed to smoothly transition between low and high pressure, may begin to stroke unevenly if these components are compromised. This uneven stroking not only affects the cutting precision but can also lead to premature wear of parts and even system failure.

To address overstroking, the first step is to reset the alarm and perform a series of checks:

1. Turn off the cutting head to stop water flow and prevent further damage.
2. Activate the pump and allow it to build pressure gradually, monitoring for any signs of irregular performance.
3. Re-engage the cutting head and observe the stroke rate of the intensifier through the operator interface or manually via proximity switches.

These actions often rectify temporary glitches. However, persistent overstroking requires a more detailed investigation into the system’s components:

• Inspect the orifice and water seals for wear or damage. These parts are crucial for maintaining consistent water pressure and flow. Replace them if necessary.
• Check for leaks in the water lines, fittings, and valves. Water leakage can reduce the system’s pressure, leading to overstroking. Repair or replace leaking components to restore proper operation.
• Evaluate water pressure gauges before and after the water filters. A significant pressure drop indicates clogged filters, which can restrict water flow and affect the intensifier’s operation. Replacing these filters can prevent overstroking by ensuring consistent water supply to the pump.

For cases where overstroking occurs in only one direction, additional steps include:

• Examine the low and high-pressure poppets corresponding to the overstroking side. These valves are critical for controlling water flow and pressure within the intensifier. Damage or wear can cause them to malfunction, leading to overstroking. Inspect these components for any signs of damage or wear and replace them as needed.

Hydraulic Temperature Increases

The Problem: Hydraulic systems are the lifeline of waterjet cutting machines, providing the necessary pressure to propel water at cutting speeds. A common issue is the increase in hydraulic fluid temperature beyond the normal operating range set by the pump manufacturer. When the temperature exceeds this limit, the fluid’s viscosity decreases, reducing its lubricity and protective qualities, which can lead to premature wear of hydraulic components.

Why It Happens: The primary suspect for unexpected hydraulic temperature rises is the cooling system. Depending on whether your system is water-cooled or air-cooled, the solutions will vary.

Solutions:

• For Water-Cooled Systems: Ensure the cooling water supply is active. Adjust the water-modulating valve to increase water flow, effectively reducing the hydraulic fluid’s temperature. Regular maintenance of the cooling system can prevent issues before they arise.
• For Air-Cooled Systems: Ambient temperature plays a significant role. If it’s too high, consider enhancing your shop’s cooling capacity, possibly with an air conditioner. Additionally, ensure the cooling fan operates efficiently; clean any clogged heat exchanger fins and check the thermal overload device on the fan motor starter for tripping.
• If cooling systems are functioning correctly, inspect the hydraulic relief valve for signs of overheating, which could indicate it’s partially opening and generating excess heat. Also, verify the condition and connection of the hydraulic fluid temperature and level sensor, ensuring it’s neither unplugged nor damaged.

Low Water Pressure

The Problem: Low water pressure, whether on the intake side to the intensifier or the output side, can significantly impact the waterjet’s ability to cut materials effectively. This might manifest as a reduced cutting speed or inability to cut through materials at all.

Why It Happens: Several factors can contribute to low water pressure, including damaged or defective orifices, leaks in the on/off valve, or issues with the intensifier’s stroke under pressure.

Solutions:

• Intensifier to Cutting Head: Check the orifice for damage and replace if necessary. Inspect the on/off valve for leaks and repair them. If the intensifier strokes under pressure with the cutting head off, look for leaks in the high-pressure tubing and bleed-down valve, repairing or replacing parts as needed. Ensure both low-pressure and high-pressure poppets are in good condition, replacing them if they show wear or damage.
• Water Supply to Intensifier: Confirm the utility water supply to the pump is operational. If the water pressure is consistently low, consider replacing water filters or checking for failures in the inlet cutting water valve.

Short Seal Life

The seals within waterjet systems play a pivotal role in maintaining high pressure and preventing water leakage. Yet, these components often suffer from shortened lifespans, leading to increased maintenance and downtime. The primary culprits behind short seal life include suboptimal water quality and inadequate water pressure. Debris and particulates can also exacerbate wear on seals and other components.

To mitigate these issues, you should ensure that your water quality adheres to recommended standards, focusing on the clarity and purity essential for preventing seal degradation. Regularly checking water pressure and volume against the manufacturer’s specifications can prevent overburdening the seals. When replacing seals, a thorough cleaning of all parts to remove debris is crucial. Additionally, inspecting the high-pressure cylinder for cracks and assessing the condition of the plunger bearing or hydraulic cartridge for wear are vital steps. Through these measures, you can significantly enhance seal longevity, ensuring that your waterjet cutter operates efficiently and reliably.

Abrasive Clogs

Abrasive clogs are a common issue in waterjet cutting systems, particularly those that utilize garnet or other abrasive materials to enhance cutting power. Clogs can occur in the mixing chamber or nozzle, leading to decreased cutting efficiency or complete blockage of the water stream. The key to preventing abrasive clogs lies in regular maintenance and proper setup. Ensuring that the abrasive feed is consistent and free from moisture is essential, as moisture can cause the abrasive particles to clump together. Regular inspection and cleaning of the abrasive delivery system can help maintain a smooth flow and prevent clogs from forming.

Misalignment of the Cutting Head

Misalignment of the cutting head can result in inaccurate cuts, reduced quality, and increased wear on the system. This issue may stem from improper installation, wear and tear on the components, or accidental bumps and adjustments during operation.

To correct and prevent misalignment, regular calibration of the cutting head is necessary. Operators should also be trained to handle the equipment carefully and perform routine checks to ensure that all components are correctly aligned.

Electrical Issues

Electrical issues in waterjet cutting systems can range from simple wiring problems to more complex issues with the control system. Symptoms may include erratic behavior of the machine, failure to start, or sudden stops during operation.

Addressing these problems often requires a thorough inspection of the electrical components, including wires, connectors, and circuit boards. In some cases, consulting with a service technician or the manufacturer’s support team may be necessary to diagnose and resolve the issue effectively.

Software and Control System Errors

Software and control system errors can disrupt the smooth operation of waterjet cutting machines, affecting their precision and reliability. These errors might manifest as incorrect cutting paths, failure to execute commands, or inability to interface with the operator’s inputs.

Regular software updates, proper configuration of the control system, and training for operators on troubleshooting techniques are vital in minimizing these errors. In more complex cases, assistance from the manufacturer or specialized technicians may be needed to resolve software-related issues.

Tips to Prevent Waterjet Cutting Problems

In the realm of manufacturing, waterjet cutting stands out for its precision, versatility, and ability to cut through a myriad of materials without inducing thermal stress. However, to harness these benefits fully, it’s crucial to preemptively address common issues that can arise during operation. Proactive measures and routine checks are not just about reducing the need for repairs; they’re about ensuring consistent, high-quality performance. Let’s dive into essential practices to keep your waterjet system running smoothly.

Understanding Your Waterjet System

Familiarize with the Machine’s Manual: The first step towards preventing waterjet cutting problems is to thoroughly understand your machine. Each model may have specific operational requirements and maintenance schedules. By familiarizing yourself with the manufacturer’s manual, you ensure that you’re not only using the machine correctly but also adhering to recommended maintenance practices.

Regular Inspection: Routine checks are your best defense against unexpected issues. This includes inspecting for water leakage, ensuring water pressure is stable, and checking the integrity of water seals and nozzles. By catching signs of wear or malfunction early, you can prevent more significant problems down the line.

Diagnosing and Fixing Nozzle Wear

Inspect Nozzle Regularly: The nozzle is a critical component of the waterjet cutter, subject to wear from the abrasive flow. Regular inspection helps identify wear patterns early, allowing for timely replacement before quality is compromised.

Check for Symmetrical Wear Patterns: Uneven wear can indicate misalignment or issues with the abrasive feed. If wear patterns are not symmetrical, it’s a sign that the nozzle may need adjustment or that there’s a problem with how abrasives are being delivered to the cutting head.

Resolving Abrasive Feed Issues

Ensure Consistent Abrasive Flow: Abrasive feed issues can lead to inconsistent cuts and increased wear on the nozzle. Verify that the feed system is delivering abrasives at the correct rate and volume. Regularly checking and calibrating the abrasive feed mechanism can help maintain a consistent flow.

Adjust Abrasive Feed Rate: Tailoring the abrasive feed rate to the material being cut and the desired cut quality can significantly impact performance. Consult your waterjet’s manual for guidelines on adjusting the feed rate according to different cutting scenarios.

Preventing and Clearing Clogs

Regular Cleaning: Clogs in the mixing tube or nozzle can disrupt the waterjet stream, affecting cut quality. Implement a cleaning routine to remove any build-up of debris or abrasive particles. This not only prevents clogs but also extends the life of these components.

Use Quality Abrasives: The quality of abrasives plays a crucial role in preventing clogs. Low-quality abrasives may break down more quickly or contain impurities that contribute to clogging. Investing in high-quality abrasives ensures a cleaner cut and reduces the likelihood of clogging.

Managing Water Quality and Pressure

Overview

The cornerstone of trouble-free water jet operation lies in the management of water quality and pressure. Ensuring that these fundamental aspects are meticulously monitored and maintained can dramatically reduce the likelihood of malfunctions and the need for extensive repairs.

• Monitor Water Quality: The purity and temperature of the water used in waterjet systems play a critical role in preventing blockages and ensuring the longevity of components. Utilizing a prefilter water pressure gauge and regularly checking for debris and particles can keep the water supply in optimal condition. Incorporating water filters and monitoring the operating temperature help maintain the system’s reliability and prevent issues related to water hardness and sediment accumulation.
• Check for Leaks: Routine inspections for water leakage in hoses, fittings, and seals are vital. Early detection of leaks not only prevents water waste but also reduces the risk of water damage to the machine and surrounding equipment. Employing water seals and regularly replacing worn parts can safeguard against unexpected leaks.
• Regulate Water Pressure: Maintaining the correct water pressure is crucial for effective cutting and system health. Using a water pressure gauge to monitor pump pressure ensures that the system operates within its specified range. Adjustments can be made via the pressure control knob, ensuring that the high pressure from the pump is effectively transmitted to the cutting head without overloading the system.

Handling Material and Mechanical Issues

Secure Materials Properly

Ineffective material securing can lead to inaccuracies in cuts and potential damage to the water jet cutter. Employing clamps and fixtures to hold materials in place ensures stability during the cutting process, enhancing both safety and precision.

Check Mechanical Components

Regular inspection of mechanical components such as the cutting head, nozzles, and intensifier is imperative. Wear and tear on these parts can significantly impact the quality of the water stream and, by extension, the quality of the cut. Replacement or repair of components showing signs of degradation ensures consistent performance and reduces the likelihood of mechanical failure.

Addressing Overstroking and Hydraulic Issues

Monitor Stroke Limits

Overstroking, or exceeding the designed stroke limits of the waterjet intensifier, can lead to premature system failure. By closely monitoring stroke rates and adjusting them as necessary, operators can prevent the mechanical stresses that lead to overstroking.

Maintain Hydraulic System

The hydraulic system, essential for generating the high pressure needed for water jet cutting, requires regular maintenance. Checking hydraulic fluids for contamination, monitoring system pressure through relief valves, and ensuring seals and hoses are in good condition are all crucial steps in preventing hydraulic issues.

Solving Electrical and Software Problems

Regular Electrical Checks

Electrical systems, including wiring, connectors, and control panels, are the backbone of waterjet operation. Routine checks for signs of wear, corrosion, or damage can prevent electrical failures that might lead to operational interruptions.

Update and Maintain Software

Software plays a critical role in the precise control of waterjet cutters. Regular updates and maintenance ensure compatibility with cutting files, reduce the chances of software-related errors, and enhance the machine’s capabilities through new features and improvements.

Optimizing Cutting Parameters

Adjust Cutting Speed

The speed at which a waterjet cuts material greatly influences the quality of the finished product. Too fast, and the cut may be rough or incomplete; too slow, and the material may suffer from excessive wear or thermal distortion. Finding the optimal speed requires balancing the characteristics of the material with the capabilities of the waterjet.

Fine-Tune Standoff Distance

The distance between the nozzle and the material being cut, known as the standoff distance, can affect the precision and quality of the cut. Adjusting this distance allows for greater control over the water stream, reducing the occurrence of taper and striations in the cut edge.

Implementing Preventive Maintenance

Develop a Maintenance Schedule

A structured maintenance schedule is key to the longevity and reliability of waterjet systems. Regularly scheduled check-ups ensure that potential issues are identified and addressed before they can escalate into major problems.

Train Operators

Knowledgeable operators are the first line of defense against water jet cutting issues. Comprehensive training on machine operation, troubleshooting tips, and maintenance procedures empowers operators to detect and resolve minor issues before they require professional intervention.

Seeking Professional Help

Contact Manufacturer Support

When faced with complex issues beyond the scope of routine maintenance and troubleshooting, reaching out to the manufacturer or a certified service technician is advisable. Professional assistance ensures that repairs are carried out effectively, reducing the risk of further damage and ensuring the machine’s return to optimal operation.

Conclusion

The intricate dance of maintaining a water jet cutter involves a symphony of checks, balances, and proactive measures. From the careful management of water quality and pressure to the meticulous maintenance of mechanical and hydraulic systems, each step is a testament to the operator’s commitment to precision, efficiency, and longevity. By adhering to these guidelines, fabricators can ensure their waterjet systems operate at peak performance, delivering on the promise of precision cutting across a spectrum of materials and applications. In the realm of waterjet cutting, attention to detail and a commitment to maintenance are not just best practices; they are essential to the art and science of shaping the world’s materials.

The post Waterjet Cutting Problems: All Issues and Solutions appeared first on TechniWaterjet.

Therefore, it is essential to understand ‘what is a water jet nozzle?’ and its many different types. This article will explore all there is to know about waterjet nozzles, their types, specifications, materials, and a guide to selecting the best one.

What is a Waterjet Nozzle?

A waterjet nozzle is the part that focuses the water stream on the desired workpiece location. It is the final part of the water delivery system of the machine.

It is also known as the focusing tube or the mixing tube. The waterjet nozzle is made of extremely sturdy construction to handle the ultra-high hydraulic power involved with waterjet cutting.

Due to the highly pressurized water, nozzle wear is common in waterjet cutting. Therefore, the water jet nozzle is a machine part that requires periodic replacement.

What is the Purpose of the Water Jet Nozzle?

The purpose of the water jet nozzle is to focus the water stream on the workpiece. The optimal width of the water stream for cutting varies for every material and thickness.

Therefore, a nozzle ensures you can use the appropriate water jet nozzle for the best cutting result. The nozzle contains a jewel orifice for the exit of the water stream. This helps in the longer lifespan of the entire assembly.

What are the Different Types of Nozzles?

There are two different types of water jet nozzles. These are:

Pure Water Jet Nozzle

A pure water jet nozzle is used in waterjet cutting that does not use any abrasive. It applies in waterjet cutting of soft materials like paper, foam, rubber, textiles, cardboard, and plastics that do not need abrasive waterjet cutting.

Due to the absence of abrasive particles, the size of the orifice can be extremely narrow.

Abrasive Water Jet Nozzle

An abrasive water jet nozzle is used in the abrasive waterjet cutting of hard materials that the force of the water alone cannot cut feasibly. An abrasive jet nozzle design differs greatly from a pure water jet nozzle.

An abrasive jet nozzle has an additional mixing chamber where the abrasive particles are introduced in the water. There is an inlet into the nozzle for the entry of abrasive particles.

The purpose of the high-pressure water is for the acceleration of the abrasive particles. The material is cut with high-velocity abrasive particles Commonly cut materials with abrasive jet nozzles are metals, alloys, ceramics, composites, stone, glass, etc.

Specifications of a Water Jet Nozzle

There are many technical specifications to learn about water jet nozzles to understand how to differentiate between the different options. These specifications are:

Orifice Diameter

The orifice diameter is the width of the gap in the jewel orifice. A lower orifice diameter means a more narrow water jet stream. Using a small orifice diameter will create a higher-pressure water jet. However, it will also increase the nozzle wear tremendously. This creates a more frequent need for nozzle replacement.

What is the diameter of a water jet cutting nozzle?

The diameter of a water jet cutting nozzle is generally three times the nozzle orifice diameter.

The nozzle orifice diameter is kept small enough to keep the kerf width minimum and accuracy at the maximum.

However, the value should not be too small because it will reduce the cutting speed and increase nozzle wear.

Flow Rate

The flow rate is defined as the water volume that goes through the orifice per unit time. Flow rate is a numerical value measured in Litre per minute (LPM) or Gallons per minute (GPM). A higher flow rate increases the speed of the waterjet cutting. However, it also increases the nozzle wear.

Nozzle Size

The nozzle size refers to the width of the nozzle bore hole. This value is three times the orifice diameter. The size of the water jet cutting nozzles can be divided into three segments:

• Small Nozzles: A small nozzle is used when high accuracy or intricate details are required in the water jet cutting process. The diameter of these nozzles can range from 0.254 mm to 1.016 mm (0.01 in to 0.04 in). Small nozzles provide a higher control of the cutting process.
• Medium Nozzles: Medium nozzles are used when working on surfaces or during general cutting operation. The precision is not the primary requirement for the medium nozzle cutting operation. The nozzle bore diameter can vary between 1.016 mm to 2.032 mm (0.04 in to 0.08 in).
• Large Nozzle: Large nozzle is used when high speed cutting is the primary requirement. They can process bulk material cutting at a rapid rate. The nozzle bore diameter ranges from 2.032 mm to 6.35 mm (0.08 in to 0.25 in).

Pressure Rating

Pressure rating is the maximum amount of water pressure that the nozzle can handle optimally. Exceeding the water pressure beyond this limit can degrade the nozzle severely and even cause nozzle breakdown. The pressure rating can vary from nozzle to nozzle. The manufacturers provide this value with the replacement nozzle.

How much pressure is in a waterjet nozzle?

Modern waterjet cutting nozzle can reach pressures as high as 90,000 psi. However, such extreme values cause wear of all the internal components, including the nozzle. Water pressures between 40,000 psi to 60,000 psi are considered the best for optimal performance and long life of the nozzle.

What Material Is Used For Making Waterjet Nozzles?

There are many different options for waterjet nozzle materials. The exact choice of material can vary depending on the intended lifespan, pressure rating, applications, and cost limits. Common materials for waterjet nozzle are:

Tungsten Carbide: Tungsten Carbide is the most popular material for waterjet nozzles. Tungsten Carbide nozzles fare exceptionally well in terms of performance and strength. The hardness of Tungsten Carbide is similar to diamond. Tungsten Carbide nozzles are rated for extreme waterjet pressures up to 90,000 psi. With ideal usage, Tungsten Carbide nozzles can last for over 200 hours. With rough use, these nozzles can require replacement after 100 hours.

Sapphire: Sapphire nozzles provide high durability and an affordable cost. Additionally, these nozzles are completely chemically inert. The lifespan of these nozzles is at the shorter end of the scale, lasting for around 50 to 100 hours. These nozzles are good up to 60,000 psi to 70,000 psi water pressure. Ruby nozzles in the market also have identical properties to the sapphire nozzles.

Diamond: Diamond nozzles are the best in terms of durability and hardness. These nozzles can withstand the most extreme water pressures and the hardest abrasives. The lifespan of these nozzles is also the longest. It is common for many diamond nozzles to come with a 1000 hour life expectancy. These nozzles are also the most expensive choice, costing around twenty times more than sapphire nozzles. They can be cost-effective in bulk abrasive jet cutting of very hard materials.

Ceramics: Ceramic nozzles are emerging as an innovative material choice for waterjet cutting. These nozzles can be even more durable than hardened steel. These nozzles are completely corrosion-resistant. The lifespan of a ceramic nozzle depends on the material used in the particular nozzle.

Nozzle Connection Type

There are multiple connection types available for waterjet cutting nozzles Two of the most common connection types are:

• Threaded Nozzles: Threaded connection has screw-like threads on the nozzle connector ends. This requires a proper tooling to fit and remove the nozzles. However, threaded nozzles can handle extreme pressures and are completely leak-free with proper fitting. Threaded nozzles ensure that there are no accidental disconnects during operation.
• Quick-Connect Snap Nozzles: Quick-connect snap nozzles are also marketed as quick-disconnect nozzles. These nozzle couplings don’t require dedicated tools for fitting or dismantling the nozzle. These are completely unthreaded nozzles. There are generally snap mechanisms in place that can lock the nozzle on the machine. Generally, quick-connect nozzles cannot handle ultra high pressure like the threaded nozzle. However, quick-connect nozzles are very convenient to use and replace. The mechanical locks can sometimes accidentally disconnect during operation.
• Quick-Connect Screw Nozzles: Quick connect screw nozzles are threaded variations of the snap nozzles. There are locking mechanisms in place but the nozzle requires additional screwing, which is fairly easy. These nozzles are more secure than snap nozzles and don’t disconnect during operation.

What Materials Can a Waterjet Nozzle Cut?

Waterjet nozzles can cut through virtually any material. Some of the common materials are:

• Metals: Waterjet is able to cut through the hardest metals and metal alloys such as hardened steel. Metal cutting requires an abrasive jet nozzle for a smooth and fast operation.
• Ceramic: Waterjet cutting is commonly used for cutting ceramic tiles and stone. It may use an abrasive jet nozzle or a pure waterjet nozzle, depending on the type of ceramic.
• Glass: Waterjet cutting glass is common in art, construction, decor, and many other sectors. Abrasive jet nozzles can cut through any glass, including bullet proof glass.
• Rubber: Waterjet is a great way to cut rubber. Rubber can be cut with a pure waterjet nozzle at low pressures. This makes it a very cost-effective option.
• Plastics: Waterjet can cut through any plastic without heating it. Plastic cutting usually requires an abrasive jet nozzle.
• Foam: Waterjet cutting foam creates very clean cuts without any burn marks. It is a cheap cutting method using a pure waterjet nozzle.
• Thin Films: Waterjet is a great way to cut very thin foils and films (such as aluminum foil). A pure waterjet nozzle is enough for cutting thin foils even made of metals.
• Wood: Soft or thin wood can be cut with a pure waterjet nozzle. Hardwoods or very thick woods require an abrasive jet nozzle.

How to Choose the Right Waterjet Nozzle?

Choosing the right waterjet nozzle should be done considering several factors. These factors are:

• Application: The primary decision for choosing the right nozzle is based on the particular application. Certain applications can straightaway eliminate many of the available nozzle options. For instance, applications involving high pressures cannot use snap connection type nozzles.
• Material: There are many different options for the nozzle material. Choose a suitable material based on whether or not you would be using an abrasive. Factor in how often you want to make nozzle replacements. Different materials have different lifespans. If you don’t mind investing in quality, diamond can be a good choice. Tungsten Carbides are tried and tested nozzles that are the most commonly used.
• Orifice Size: The size of the orifice is also very application specific. The size depends on the type of material and its thickness. There is no standard orifice size suited for all applications. Find out the orifice size based on manufacturers instructions or by trying different options for your use cases.
• Pressure Rating: Once you have decided on a nozzle, ensure its maximum pressure rating is safely above the water pressure you use.
• Manufacturer: Opting for a trusted and reliable manufacturer is always recommended instead of a third-party option. Manufacturers such as Techni Waterjet provide long-term reliability with spare part availability and technical support when needed.

How Long Does a Waterjet Nozzle Last?

A waterjet nozzle can last anywhere from 40 hours to 1000 hours. The lifespan mainly depends on the nozzle material and the usage conditions.

Misusing the nozzle can significantly degrade its performance and provide a lower lifespan.

What is the Cost of a Water Jet Nozzle?

The cost of a waterjet nozzle can start at $20 and go over $400. The price of the nozzle is not a direct relation to its cost-effectiveness.

A $400 diamond nozzle might be more cost-effective than a $20 sapphire nozzle due to its longer lifespan and less downtime due to replacements.

Therefore, the running cost of the nozzle varies depending on the particular use case. Tungsten Carbide nozzles are a good middle ground, costing around $50 to $100.

Endnotes

The nozzle is an integral part of a water jet system. The tiny hole in the nozzle focusing tube is responsible for the high-speed water that can pierce through the hardest materials.

However, choosing the wrong nozzle can lead to disastrous results such as poor accuracy, sharp corners, water spread, and slow cutting speeds. Follow the information above to get the best nozzle fit for your project.

Feel free to contact us if you need an expert advice. Our team is always ready to help!

The post What is a Water Jet Nozzle: Definition, Types, Materials & Specifications appeared first on TechniWaterjet.

Waterjet cutting is effortless to adapt in any industrial setting. However, some waterjet cutting tips and trick can help improve the results for beginners and professionals alike. This article will go through these tips for improving the pure and abrasive waterjet cutting performance.

Top Tips to Maximize Waterjet Cutting Productivity

Each of the following tips can be very useful when cutting any material with the waterjet cutting process:

1. Parameter Selection: Parameters like the cutting speed and the abrasive flow rate are based on the use cases. There is no universal ideal value. Try various settings on your application-based test cases to determine which value will give the best result for you. You can note down that value and use it for future cutting.

2. Stacking: You can place multiple sheets of material on each other to cut them simultaneously. This process is called stacking. Stacking can increase the productivity of the whole operation exponentially. However, it is only applied when multiple pieces of the same shape are required consistently.

3. Material Orientation: The orientation of the material can significantly influence the cutting quality. Cutting across the grain will produce different results than cutting against it. Try different orientations for the material being cut to determine which will create the best outcome.

4. Operator Skill: A skilled operator can get the most out of a waterjet machine’s capability. At the same time, an unskilled operator can create disastrous results even from high-end waterjet machines. It’s essential to ensure your operator is highly skilled and has the necessary training to work on the machine.

However, the importance of ongoing learning and adaptation can’t be overstated. The field of waterjet cutting is continually advancing, with new techniques and technologies emerging regularly.

Regular training programs, workshops, and industry events can be valuable resources for staying updated with the latest trends and improvements in the waterjet cutting process.

5. Piercing Point: For a high quality cut, use a pierce point inside the area that will be cut out. This helps in providing precision cutting as well. If you directly cut the material at the cut location, the initial starting point will have a higher kerf width.

6. Taper: Thick materials show the phenomenon of taper during cutting with a waterjet. This happens due to the spread of the waterjet stream as it travels vertically. Account for taper when adjusting the cutting parameters. Modern software have automated adjustments for taper deviation.

7. Material Usage: When cutting out multiple pieces from a single sheet, use the software to arrange cutouts to get most out of the material and generate minimal waste.

8. Supports: The workpiece requires proper support during the cutting process. Insufficient or loose support fixtures can cause warping and bending of the material. Lack of support or improper support can also cause vibrations, reducing precision. Supports can include jigs, fixturing, clamps, or an alignment guide.

9. Safety Process: Ensure that the operator is trained in the safety procedure for the machine. Additionally, ensure the machine has safeguards like light curtains or guard railings. Waterjet machines also require safety goggles to protect the eyes from the water splatter.

10. Selecting Material: If there is an option for choosing between different materials, choose a material that is easier to machine. Waterjet cutting can cut hard and thick materials. However, materials with good machinability can provide faster cutting speed.

11. Lead-in and Lead-out: Understand using lead-in and lead-out to optimize material usage while keeping the cut quality high. The lead-in and lead-out points should be outside the production part so as to not create any scarring on the part itself. However, the distance of these points from the part should not be excessive as it would create added material waste.

12. Choosing Lead-in and Lead-out Points: Lead-in and lead-out points should not be arbitrary. The best location for these points is on the material area that will go to waste. If these points have to come inside the production part, choose an area where the quality is unimportant, such as features that will not be visible to the eye.

13. Brittle Material: Brittle materials can have excessive chipping when the waterjet cutting starts and the machine adjusts the flow rate and water pressure. Therefore, brittle material requires additional lead-in distance. If there is insufficient lead-in, chipping will occur inside the production part area.

14. Single vs. Dual Cutting Head: Dual cutting head can create faster cuts. However, equating the water pressure between the two cutting heads can be difficult. Therefore, the cutting quality can deteriorate. It is better to choose a single cutting head, making it easier for the operator to oversee the process.

15. Maintaining Logs: When making changes to any cutting parameter like water pressure or abrasive flow rate, note down the value that you are using. This helps in later iterations to create the same result or to avoid any problems. It can also provide a reference point to understand which direction to choose for getting the desired result.

16. Air Gaps: When stacking thin materials, ensure that the parts are layered together without any gap in between. Air gaps higher than 0.020 inches can cause poor cutting on the bottom layer. This is because the water stream tends to spread out in the air gap.

17. Underwater Cutting: Cutting underwater is a great way to eliminate the noise generated in a waterjet cutting. It will also eliminate any water splatter, which is a common problem with waterjet technology. Another benefit is that underwater waterjet cutting will avoid any unwanted surface frost effects.

18. Nozzle Cleaning: The nozzle is prone to getting clogged due to debris and impurities present in the water. It is important to clean the nozzle regularly to ensure the cutting results are up to the standards.

19. Nozzle Inspection: The nozzle will wear out with the use due to the extreme pressure of the water. Inspect the nozzle regularly and change it when the wear is excessive. The manufacturer’s manual will provide detailed guidelines to change the nozzle for your particular waterjet machine.

20. Tool Path Optimisation: Use the waterjet software to optimize the tool path for the cutting process. Remove any unnecessary movement of the cutting heads. Additionally, it is better to use single-pass waterjet cutting than to use multiple passes. Extra tool movement increases abrasive usage, which builds up the operation costs of abrasive waterjet cutting. It also increases tool wear and decreases precision.

21. Test Cut: Waterjet cutting provides different results for different materials, water pressure, and various settings. Therefore, before cutting the actual part, always do a test run to find out how the machine is performing and if any variation is required.

22. HP vs. Psi: A common confusion occurs when choosing between a higher horsepower or a high pressure. A common rule of thumb is to go with a high horsepower when seeking a rapid increase in cutting speed. A high waterjet pressure will not increase cutting speed substantially, but it will increase the cutting efficiency.

23. Water Quality: Water quality can be essential in waterjet cutting. Treating the input water before feeding it into the machine is recommended. The ideal Total Dissolved Solids (TDM) of the water should be less than 100 ppm. The ideal value of silica in the water is 1 ppm. Water with poor quality will still cut the workpiece. However, it can degrade the parts of the machine at a faster rate.

24. Water Temperature: The extreme pressure used in waterjet cutting can lead to the water reaching high temperatures. This degrades the seals and other parts inside the intensifier pump. Using cool water for the cutting process can reduce this problem. The ideal temperature of water fed to the direct drive pump is 21.1° C.

If the water temperature exceeds the ideal value in a waterjet cutting system, it can have several negative impacts:

1. System Damage: Higher temperatures can cause premature wear and damage to the waterjet system’s components. This is especially true for seals and other parts inside the intensifier pump, which can degrade faster under high-temperature conditions. This can lead to frequent equipment breakdowns and increased maintenance costs.
2. Reduced Efficiency: The effectiveness and efficiency of the waterjet cutting process can decrease as the temperature of the water increases. High temperatures can alter the water’s properties, affecting the precision and speed of the cutting process.
3. Safety Concerns: Overheating can also lead to safety issues. For instance, very high temperatures could potentially cause a fire hazard in certain situations.

25. Abrasive Flowrate: The cost of abrasive is the major operating cost in abrasive waterjet cutting. However, this does not mean you can reduce costs by lowering the abrasive flow rate. Lowering the abrasive flow rate will significantly increase other costs due to a longer cutting time. Therefore, use the best abrasive flow rate for faster and high-efficiency cutting.

26. Protection Covers: Install a protection cutter on the cutting head. A protection cutter will protect the cutting head from damaging particles in abrasive waterjet cutting. It also protects against water backsplash and debris from damaging the machine parts.

27. Cutting Laminates: Cutting of laminates always brings the risk of delamination. You can avoid this with waterjet cutting by beginning the cut from the sides instead of the middle of the workpiece.

28. Spare Parts: It is a good idea to have spare parts for various components of the waterjet cutting machine. Having spare parts will avoid any downtimes during part failure. In addition, the operator should learn the basic fixes and repairs for the machine.

29. Soundproofing: Waterjet machines can cause a lot of noise pollution. It is a good idea to use soundproofing panels on the workshop walls to avoid noise pollution in the vicinity.

30. Software Update: It is common for waterjet cutting software to get new features. You can update the software to get these features. New updates can also improve the cutting tool path movement and efficiency.

31. Correct Abrasive: Multiple abrasive size options are available in the market. A good quality abrasive will have a uniform size of the particles, resulting in a uniform cut. The smaller abrasive size will create smooth and high-quality cuts. 120 mesh abrasive can be the best fit for most requirements. However, a smaller abrasive will have a slower cutting speed.

Endnotes

Follow the tips above to improve the quality of your cutting operation significantly. These tips will also eliminate most problems of the waterjet machine, reducing downtime and repairs. Most of these tips are easy to incorporate into your daily waterjet cutting process.

If you have more questions or are interested in learning more about optimizing your waterjet cutting process, don’t hesitate to get in touch with our team at Techni Waterjet.

We’re always here to assist you in improving your industrial cutting operations.”

The post Waterjet Cutting Tips: 31 Tricks to Optimize Your Process appeared first on TechniWaterjet.

The post What is Computer Numerical Control (CNC): Definition, Components & Operations appeared first on TechniWaterjet.

Professionals often wonder about the capabilities of CNC waterjet cutting. Some common queries are what is CNC waterjet, its types, the different materials that undergo this process, and its performance. This article will explore all these answers and more.

What is a CNC Waterjet?

CNC waterjet is an automated cutting machine based on waterjet cutting technology that uses the force of highly pressurized water for material cutting.

The waterjet is controlled with Computer Numerical Control (CNC) technoogy. CNC programs are pre-written for the particular part beforehand. CNC waterjet is a fully automated, high-precision industrial cutting process.

For cutting soft materials, the force of the water is sufficient. However, for hard materials, the force of the water can lead to a slower cutting process. Therefore, abrasive material is added to the water stream to speed up the cutting action. The process is then called abrasive water jet cutting. CNC can control both pure and abrasive water jet cutting.

How Does a CNC Waterjet Cutter Work?

CNC waterjet cutting is a multistage process. The steps involved are:

1. Designing the Part

An engineering design of the part is created before cutting it. For simple cuts in a straight line, this step can be skipped. However, a detailed graphical design with the measurements is required for complex parts. The graphical design is made in Computer Aided Design (CAD) software.

2. Converting Design to CAM

A CNC waterjet machine does not understand graphical design. It understands CAM language (g-code and m-code). Therefore, the CAD design is converted to CAM in Computer Aided Manufacturing (CAM) software. The CAM file is loaded to the machine control panels.

3. Machine Setup

The operator starts the machine setup for the operations. The workpiece is clamped on the worktable. All the necessary settings are selected and preliminary checks are done.

4. Machine Startup

The machine startup process takes place according to the particular CNC waterjet model. Startup includes the generation of pressure in the hydraulic pump. The hydraulic pump provides pressurized hydraulic oil of around 50 psi to the intensifier. The intensifier increases the hydraulic pressure to 50,000 psi and even more.

5. Execution of Waterjet Cutting

Once the pressure is ready, the cutting operator starts. The water jet cutting head moves around the part while forcing the high-pressure stream of water. The G-code of the CAM file controls the movement. The stream of water is very narrow with a thickness less than a human hair.

6. Unmounting of Part

Once the machining is completed, the part is unmounted from the machine. If the part requires any further machining, the operator mounts it on the worktable again. Otherwise, the part is sent for secondary machining.

What are the Parts of a CNC Waterjet Cutter

CNC waterjet cutting machine comprises of industrial-grade parts that can handle the ultra-high erosion forces at play. The various components of water jet cutting machines are:

CNC Controller

The CNC controller is the brain behind the machine. It reads the commands provided by the software and the settings made by the operator. The combined interpretation is sent to the machine cutting head.

High-pressure Pump

A high-pressure pump creates the necessary force required for the cutting action. It is an assembly of a hydraulic pump and intensifier. The hydraulic pump creates a small pressure which is amplified by the intensifier. The cost of the water jet heavily relies on this part. High-pressure pumps come under multiple settings to adjust the pressure according to part requirements.

Cutting Head

The cutting head is the assembly that moves the stream of water around the work table. A nozzle present in the cutting head focuses the stream of water. There is a mixing chamber before the nozzle in abrasive water jet cutting. The mixing chamber mixes the abrasive material with the water stream.

Abrasive Hopper

The purpose of an abrasive hopper is to store and feed the abrasive material to the mixing chamber. A good quality abrasive hopper can deliver the abrasive material uniformly. Abrasive hoppers can generally store enough material for hours of waterjet cutting.

Gantry

The gantry is the bridge system in the waterjet cutting machine. It provides support to the cutting head and mobile parts of the machine. The gantry bridge system supports the cutting head movement in the X-axis, Y-axis, and Z-axis.

Cutting Table

The cutting table provides a stable base for mounting the workpiece. The workpiece is held securely on the cutting table. Modern waterjet cutters have the feature of underwater cutting. The workpiece can be submerged underwater to provide noiseless and splatter-free cutting.

Water Filtration System

The water filtration system purifies the water and removes any debris from it. This prolongs the life of the components used in the waterjet cutting machine. A water filtration system usually includes a softener for fixing the hardness of the water. The filtration system should be designed based on the type of water source you will use.

Control Panel

The control panel provides a medium for the operator to interact with the machine. Various settings of the waterjet machine can be selected through the control panel. Control panels also come with a display for viewing relevant information.

Software

Waterjet machines come with a software that acts as the language between the controller, the operator, and the machine. The functionality of the software can vary based on the machine. Every Techni Waterjet cutting machine comes with complimentary software. The software contains many basic cutting shapes preloaded in the system.

Different Types of CNC Water Jet Cutting Machines

CNC water jet cutting machines are available in many different configurations. The use of a particular type is based on the requirement of the operation. These different types of machines are:

One-dimensional Waterjet Cutting

One-dimensional waterjet cutting can also be seen as single-axis cutting. In this method, the waterjet cutting heads can only move in one direction. This method is used for straight linear cuts. Generally, this technique is applied to the processing of raw materials.

Two-dimensional Waterjet Cutting

Two-dimensional waterjet cutting is also known as 2-axis waterjet cutting. The cutting head can move on the X-axis and Y-axis. These machines can cut linear as well as circular cuts. However, they cannot create inclined surfaces or curved cuts in the vertical plane.

3-axis Waterjet Cutting

3-axis waterjet cutting machine can move the cutting head in the X-axis, Y-axis, and Z-axis. The X-axis is left and right movement across the worktable. The Y-axis is the top and bottom movement across the worktable. The Z-axis is the vertical movement perpendicular to the worktable.

4-axis Waterjet Cutting

4-axis waterjet cutter can move in the linear X-axis, Y-axis, and Z-axis. In addition, it can also move in the rotary A-axis. A-axis is the circular axis around the X-axis. 4-axis waterjet cutting can make curved cuts and machine five sides of the workpiece.

5-axis Waterjet Cutting

A 5-axis waterjet cutting machine is the most capable option among the different types. It can cut linearly in the X-axis, Y-axis, and Z-axis. In addition, the cutting head can also move in any two of the A-axis, B-axis, and C-axis. A-axis is rotary around the X-axis, the B-axis rotary around the Y-axis, and the C-axis rotary around the Z-axis. 5-axis cutters can create linear, curved, and inclined parts. It can also craft parts with internal features and geometries.

What Materials Can a CNC Waterjet Cut?

Waterjet cutting can cut through virtually any material except for only diamond and tempered glass. Some of the common materials that undergo waterjet cutting process are:

Metals

Metals and metal alloys commonly undergo waterjet cutting process. Some of the common metals utilizing this technique are:

• Stainless Steel (all grades)
• Aluminum
• Carbon Steel
• Mild Steel
• Tool Steel
• Copper
• Brass
• Iron
• Chrome
• Nickel
• Titanium
• Platinum
• Gold

Glass

Glass can be delicate to cut through traditional means. However, waterjet cutting can pierce and smoothly cut any type of glass with ease. Some common examples are:

• Plain glass
• Frosted glass
• Reinforced glass
• Mirrors
• Glassware

Stone

Waterjet cutting stone and tiles is a very common application of the method. It finds common application in kitchen countertops, flooring, cladding, and other areas. Some of the common stone and tiles cut by CNC waterjet cutting process are:

• Marble
• Granite
• Tiles
• Porcelain
• Silestone
• Caesarstone

Composites

Composite metals are made by fusing multiple materials together. Composites can be tough materials for conventional cutting processes. However, waterjet cutting can easily cut it. Some of the common composites cut with water jet cutting are:

• Fiberglass
• Fibre Reinforced Plastics
• Carbon Fiber

Plastics

Water jet cutting provides a lot of benefits when cutting plastics. CNC waterjet is a cold cutting method. Therefore, plastics do not release toxic fumes on being cut with water jet cutting. Some of the common plastics that undergo water jet cutting are:

• ABS
• Styrene
• Polythene
• LHDP
• UHDP
• Nylon

Rubber

CNC waterjet cutting also shows exceptional performance when cutting rubber. While rubbers are soft materials, conventional cutting processes create heat which can cause the rubber to harden. However, waterjet causes no such issue. It can cut any rubber with extreme precision.

Paper Products

CNC waterjet cutting is common in the paper industry. It applies to paper, paper reams, and paper based products like cardboard. Due to the softness of paper products, pure water jet cutting is enough to accomplish the task.

Wood

CNC waterjet cutting of wood is usually implemented in the furniture industry. Water jet cutting process can create intricate shapes from wood, such as carvings. Waterjet cutting can also cut plywood without causing any delamination issues.

What is the Maximum Thickness of CNC Water Jet Cutting For Different Materials?

Waterjet can cut most materials up to 24″ in thickness. The range of maximum thickness of water jet cutting varies based on the type of material. For instance, it can cut hard metals and alloys up to a thickness 12″ to 18″ (depending on the machine). It can cut soft materials many times that thickness.

The maximum thickness does not mean that a water jet machine is limited to that value. Theoretically, the water jet cutting process can cut any thickness of any material. However, the cutting time increases significantly beyond a certain thickness. Additionally, thicker materials lead to slower cutting speed. The maximum thickness is the value after which the cutting speed and time can become unfeasible.

How Accurate is CNC Waterjet Cutting?

CNC waterjet cutting can have a tolerance as low as ± 0.002”. This makes CNC waterjet cutting one of the most accurate cutting methods. The exact tolerance of water jet cutting process depends on the particular material being cut. Maintaining the machine and doing the setup right can increase the precision of waterjet cutting.

Applications of CNC Water Jet Cutting

CNC water jet cutting is used in many different industries and sectors. Some of these areas are:

• Aerospace: Water jet cutting can create the niche parts required in the aerospace industry. The high precision of water jet cutting technology makes it an attractive option for the aerospace sector.
• Automotive: Automotive industry relies on the waterjet cutting process to create precise and consistent parts. This includes everything from car frames to engine components.
• Medicine: The Waterjet cutting machine makes surgical equipment and other medical devices. Waterjet creates clean and hygienic cuts, leading to great demand in the healthcare industry.
• Electronics: The narrow thickness of waterjet cutting makes it ideal for use in the electronics industry. It commonly applies to cutting frame parts for electronic products like phones and smartphones.
• Art: The customization offered by waterjet cutting makes it ideal for cutting art products. For instance, waterjet cutting can create sculptures and architectural installations.
• Signage: Waterjet provides a smooth surface finish to the material along with superior edge quality. The signage industry uses these qualities to create brand logos, nameplates, signs, and more.
• Food and Beverage: Water jet cutting is a no-contact technology. The high hygiene of the process makes it ideal for cutting food products and in the food packaging sector.

Benefits of CNC Waterjet Cutting

The CNC water jet cutting process provides many advantages that are unmatchable with other cutting techniques. Some of these benefits are:

• No Heat-affected Zones: Heat-affected zones are caused by localized heating due to cutting friction. Water is a coolant in itself. Therefore, water jet cutting causes no heat-affected zones.
• Preserving Material Integrity: The material integrity remains intact due to the absence of heat zones. There are no burn marks on the material surface.
• Precision: The narrow stream of water results in a very high-precision cutting process. Water jet cutting has higher accuracy than alternative cutting methods.
• Edge Quality: Water jet cutting has a superior edge quality. This is the result of the material erosion that takes place on a particle level. Waterjet cut parts require no secondary finishing.
• No-contact Cutting: Water jet cutting does not require the contact of the tool with the workpiece. The high-pressure stream is enough to make the incision. This reduces the tool wear and calls for less frequent tool changes.
• Costs: Water jet cutting keeps the cost of operation manageable. Pure water jet cutting is a very cheap process. Abrasive water jet cutting has the cost of abrasive as the primary operational cost.
• Versatile: Waterjet cutter is the most versatile cutting option out there. It can handle all cutting materials regardless of their shape or form. This includes metals, non-metals, ceramics, composites, glass, paper, etc.

What is the Cost of a CNC Waterjet Machine?

The average cost of a good CNC waterjet machine is $100,000. You can find cheaper models starting at $50,000. However, these models will lack the quality and features that any job requires. Therefore, if buying a new waterjet CNC machine, $100,000 can be a good initial investment. The exact cost of CNC waterjet cutting machine can vary based on several factors.

What is the Expected Lifespan of a CNC Waterjet Cutting Machine?

Waterjet cutting machines can easily last for over 25 years. However, some parts of the machine have a shorter lifespan and require frequent replacement. These parts include the nozzle, seals, valves, tubes, and other components dealing with the high pressure stream.

What are the Safety Considerations For a CNC Water Jet Cutting Machine?

A CNC water jet cutting machine is an industrial tool. The forces it generates can cut the hardest material. Therefore, it requires extreme safety considerations. No human tissue should come under the machine during equipment operations. The machine should be operated by skilled professionals only. The operator requires safety training on the machine before using it.

Maintenance Schedule For CNC Waterjet Cutting Machine

Following the correct maintenance process for waterjet cutter can result in high quality operation and long equipment life. Some of the important maintenance considerations are:

• Check the degree of wear for parts such as nozzle before operations. A worn out nozzle can result in poor quality cuts.
• Drain the pneumatic filter regulator of the machine every week.
• Release the build-up gases in the waterjet machine every week. Water vapor buildup can be a common issue in a waterjet cutting tool.
• Regularly clean the water strainer. The frequency depends on the type of materials you cut.
• Grease the various bearings of the machine once every year.

How to Choose a CNC Water Jet Machine?

Going through a detailed buying guide for water jet machine can help in making an informed decision. Some of the important factors to consider when choosing a new water jet are:

• Pump Pressure: Pump pressure depends on the type of materials you want to cut. Required cutting speed also plays a crucial role in this.
• Abrasive vs. Pure Water Jet Cutting: Pure water jet cutting can be cheaper for soft materials. However, hard materials require abrasive waterjet technology.
• Brand Value: It is better to go with a reputed brand, even if it costs you a little extra. Machines with good build quality can avoid downtimes and operational losses.
• Spare Parts: Ensure that the spare parts for the machine are available when required.

Techni Waterjet’s G2 series is often considered the best by professionals in many different industries. These machines come with a rugged build quality and the features of waterjet machines that are twice the price range. The machines come with a complimentary software with preloaded programs for basic cut shapes.

What is the Difference Between CNC Laser and CNC Waterjet?

CNC laser and CNC waterjet both utilize Computer Numerical Control. However, there are vast differences between CNC laser and CNC waterjet cutting. The waterjet process is considerably better than laser cutting. A laser uses high-energy light rays to melt the material. This leads to adverse heat effects on the material. The materials can require secondary finishing due to burn marks.

However, the waterjet process does not create any adverse effects. Additionally, the waterjet can cut through virtually any material. CNC lasers have shortcomings in this area. Materials like plastics release toxic fumes when heated. This can damage the laser tubes, rendering CNC laser cutting unusable.

Endnotes

CNC waterjet is a breakthrough technology for cutting hard materials and soft materials. The precision and versatility of the process are very incomparable. Additionally, being a cold-cutting process, a waterjet cutter is a more attractive option than alternatives such as plasma cutting.

If you are considering getting a new machine for your fabrication shop, CNC waterjet can be the perfect choice. Get in touch with Techni Waterjet to know the right fit for your requirement.

The post What is a CNC Waterjet: Definition, Types, Price & Operations appeared first on TechniWaterjet.

This article will discuss the application of waterjet cutting for composite materials. You will learn about the different composite materials you can cut with the waterjet cutting process.

Overview of Waterjet Cutting

Waterjet is a cold-cutting technology. It uses the force of extremely high-pressure water to remove material from a workpiece. The waterjet process works for all types of materials, including metals, alloys, stone, wood, glass, composites, ceramics, and more. Waterjet technology finds application in countless sectors, such as the aerospace industry, healthcare, automotive, defense, architecture, and more.

Can You Cut Composite Materials With Waterjet Technology?

Yes, you can easily cut composites with water jet cutting technology. In fact, it is common for waterjet cutters to cut composite blocks up to 12 inches in thickness. There is no minimum thickness limit when cutting composite sheets with a waterjet. Alternative cutting processes only cut a few inches of thick composites.

The supersonic erosion of material by jet of water is very fast and precise. Abrasive materials are added to the water for harder materials. The process then turns into abrasive water jet cutting.

What are Composite Materials?

Composite materials are made by combining particles of different materials. The objective is to utilize the best properties of constituent materials. Composites usually show enhanced properties than their constituent materials. Physical strength is one of the common parameters that is improved considerably. This makes composites very hard to cut with machine tools. Composites are of two types- natural and synthetic.

What are the Common Types of Composite Materials?

Waterjet can cut through all types of composites. Some of the common composite materials that are cut using waterjet technology are:

Fiberglass

Fiberglass is a composite of plastic and glass. Glass fibers are added to plastic substances to enhance their properties. The resulting composite is stronger than many metals out there. Fiberglass can be molded into any shape required. Waterjet-cut fiberglass is used in aircraft windows, automobiles, boats, bath enclosures, pools, water tanks, surfboards, and many other components.

Carbon Fiber Reinforced Plastic (CFRP)

Carbon fiber reinforced plastic is commonly called carbon fiber or simply carbon. In CFRP, the strength of plastics is improved by adding carbon fibers. The resulting composite has an extremely high strength-to-weight ratio and stiffness. CFRP is expensive to manufacture. Therefore, waterjet cutting provides an efficient way to cut CFRP without wasting any material. Common applications of waterjet cut CFRP include making automotive frames, sports equipment, marine industry parts, cycle frames, and more.

Reinforced Concrete

Concrete is a very strong material by itself. However, adding reinforcement fibers to concrete takes its strength to the next level. Common cutting tools don’t work well on reinforced concrete. Tool breakage and accelerated wear are usual occurrences. However, the abrasive water jet can easily cut through thick concrete blocks. Waterjet-cut concrete is useful in art installations, construction, and the interior design sector.

Plastics

Plastics don’t inherently fall into the category of composite materials. Plastics become composites when reinforcements are added to it. This greatly increases the physical properties of plastics while providing a low-cost manufacturing material. However, plastic composites are negatively affected by heat. Waterjet cutting is the perfect option for cutting plastic composites since it is a cold-cutting process.

Paper

The paper industry was one of the first ones to adopt waterjet technology. Waterjet can cut very thick reams of paper without any issue. In fact, water jet also works well for other similar materials like wallpapers and textiles.

Plywood

Plywood is a composite that combines natural wood with artificial adhesive material layers. Plywood is used extensively in furniture, interiors, cabinets, construction, and other use cases. Waterjet cutters can cut multiple stacked pieces of plywood simultaneously. This is why waterjet technology is commonly used in industries manufacturing or using plywood.

Ceramic Matrix Composites

Ceramic matrix composites (CMC) include materials like alumina, silicon carbide, and mullite. These materials are brittle and can break with improper use of force. Waterjet cutting is ideal for these materials due to the highly narrow water beam. Waterjet cut CMC materials are used in heat exchangers, hot liquid filters, jet engine components, insulation, burners, and other applications.

Metal Matrix Composites

Metal matrix composites (MMC) contain fiber reinforcements spread into a base metal. Metal matrix composites have a higher toughness and damage tolerance than constituent materials. Common metals used in MMC are aluminum, magnesium, and titanium. MMC materials find use in making cutting tools, defense parts, aerospace components, consumer electronics, and marine parts.

Pros and Cons of Using Waterjet Cutting For Composites

Abrasive waterjet cutting is one of the best cutting processes for composites. The process has a lot of benefits and very few limitations. Let us go through each of these one by one:

Advantages of Waterjet Cutting For Composites

• Fast Process: Waterjet can cut composites in single-pass cutting. This speeds up the cutting process significantly.
• Versatile: Waterjet cutting can work on a wide range of materials. Therefore, a single machine can be used for multiple applications.
• Higher Production: Faster cutting speeds mean that manufacturers can produce more parts in any given time. This increases the production rate for the operation.
• Reduced Wastage: Waterjet cutting removes minimum material from the workpiece. This is due to the ultra-thin water stream. Therefore, material wastage is reduced in this process.
• High-Quality Cutting: The parts cut with a waterjet have smoother finish. This leads to the production of very high-quality parts.
• Accuracy: Waterjet technology has extreme precision and minimal kerfs. It is the go-to cutting method where secondary assembly is required.
• Cold Cutting Process: Waterjet is a cold-cutting process. There are no heat-affected zones with this technology. Therefore, there is no damage to the material in any way.
• Cost Saving: The faster production rate and reduced wastage mean manufacturers can produce parts cheaper. This makes waterjet technology a cost-saving process.
• No Cracking: Waterjet cutting works well even on extremely thin material thickness. Thin wafers of composite materials don’t crack when cut with a water jet.
• Dust Containment: The material removed in water jet cutting gets dissolved in the water. It leads to a dust-free workplace. Alternative cutting technologies tend to dirty the workplace. For instance, cutting CFRP with conventional methods creates a lot of carbon fiber dust. Waterjet dissolves the carbon dust, which can be strained later.
• Safety: Workers do not have to handle the waterjet cutting tool. The entire machinery is controlled automatically with CNC software. Therefore, this process has very high safety standards.
• No Distortion: The lack of heat-affected zones means there is no possibility of heat distortion or warping in the material.
• Stacking: You can stack multiple layers of material and cut them together. This works when same shape is required from multiple layers of material. It leads to exponential increase in production speed.

Disadvantages of Waterjet Cutting For Composites

• Pilot Hole: Waterjet cutting requires starting from the workpiece edge. If that is impossible, you must drill a pilot hole in the workpiece with the initial water beam.
• Tempered Glass: Tempered glass and diamonds are the sole exclusions for waterjet cutting. Tempered glass punctures on impact. Therefore, the waterjet stream cannot cut it.
• Operator Skill: Waterjet machines require a skilled operator for optimum results.

Applications of Waterjet Cutting of Composites

Waterjet works on a large range of materials. Therefore, many industries have utilized this technology for several use cases. Some of these use cases of waterjet technology are:

Architecture and Construction

• Cutting concrete panels for building sites
• Shower enclosures
• Bath tubs
• Wash basins
• Sinks
• Stone Countertops
• Pool panels
• Tiles

Sports Industry

• Badminton and tennis rackets
• Fishing poles
• Golf clubs
• Cricket bats
• Surfboards
• Skiing gear

Aviation and Aerospace

• Aircraft windows
• Frame
• Turbine blades
• Heat exchanges
• Insulators

Automobile Industry

• Racing car bodies
• Windows
• Display panel covers
• Dashboard

Furniture

• Cabinets
• Outdoor furniture
• Recreational equipment

Defense

• Kevlar based parts
• Apparel

How to Choose Waterjet Cutter For Composite Cutting?

Cutting composites can be as challenging as the toughest metals. Therefore, you must choose the right water jet equipment for the job. Here are some of the considerations that you should keep in mind:

Pure vs. Abrasive Waterjet Cutting

Softer composites like paper cardboard can be cut using a pure waterjet machine. On the other hand, harder composites like fiberglass will require an abrasive waterjet. Pure waterjet is cheaper and has reduced tooling costs. Consider the type of waterjet cutter you require.

Pump Pressure

Pump pressure has a major impact on the machine’s cost. The pump pressure is very application specific. Find the appropriate water pressure requirement for your job. It will save on the initial costs and provide better cutting results.

Build Quality

Waterjet cutters are a significant investment. Therefore, investing in a high-quality machine is always recommended. Superior build quality will avoid machine breakdowns and reduce maintenance costs significantly. It is better to spend a little extra towards build quality initially. Otherwise, you will pay that amount many times over during later repairs.

Features

Additional features such as underwater cutting, safety measures, vacuum assist valve, and software support can be useful. Underwater cutting in itself creates a quieter and dust-free workplace. Therefore, check the added features that your product offers.

Where to Find a Waterjet Cutting Machine?

Techni Waterjet is the leading supplier of waterjet equipment globally. These machines are very high quality with multiple safety levels. Every Techni Waterjet machine comes with complimentary software preloaded with basic cut shapes. You can add your own customized shapes and create any complex cuts required. All spare parts are available promptly whenever required.

Conclusion

Waterjet cutting is the best solution when it comes to cutting composites. The time and raw material savings with this method are tremendous. Other benefits of waterjet technology make alternative cutting processes feel very old school in comparison. Therefore, if you are searching for a cutting method for composites, look no further than waterjet. Contact Techni Waterjet to find the best machine for your requirements.

The post Water Jet Cutting For Composite Materials: Types, Applications & Benefits appeared first on TechniWaterjet.

This article will explain the various water jet machine sizes. Based on the information presented here, you can determine which size will suit your requirements.

What is Waterjet Cutting?

Waterjet cutting is a process that uses the force of a high-pressure water supply to erode material from a workpiece. Waterjet cutting does not require physical contact of the workpiece with traditional tools. Instead, cutting occurs from a distance, and only the waterjet stream makes contact with the workpiece material. Abrasive materials are added to the water to facilitate quickly cutting harder materials. The process is then called abrasive waterjet cutting.

What are the Different Sizes of Waterjet Cutting Machines?

Waterjet cutting machines do not have a formal size classification. However, these machines can be divided into four informal categories. These categories are based on the table size of the machine. Let us go through these categories one by one.

Small Waterjet Machines

Small waterjet machines have a table size of up to 1.2 m x 1.2 m (4 x 4 feet). Small workshops install these machines for short projects. Many worships use these machines to test the technology or save the initial investment.

Advantages of Small Waterjet Machines

• Initial Investment: Small waterjet machines require little initial investment. These are enticing options for manufacturers who cannot afford the high cost of big machines.
• Multiple Machines: Workshops can install two small waterjet cutters at the cost of a single large machine. This leads to a doubling of the production rate.
• Learning Waterjet: Small waterjet machines are a great way for newcomers in the industry to learn this technology. They can experiment with ways to use the machine and its settings for the best possible operation.
• Movable: Small waterjet machines can easily move around the shop if the layout plan changes. This makes it preferable for workshops looking at a growing or changing landscape.
• Precision: These machines provide a higher precision since they work on a smaller scale than their larger counterparts.
• Less Pressure Loss: Small waterjet machines reduce the travel area for the water. This reduces the pressure loss of the machine.
• Faster Cutting: Small waterjet machines can cut faster due to reduced pressure loss.

Disadvantages of Small Waterjet Machines

• Cutting Area: The disadvantage of small waterjet machines is the limitation on the area of workpiece materials. Many small waterjet machines overcome this limitation by providing a feeding mechanism for larger workpiece materials.

Applications of Small Waterjet Machines

Small waterjet machines can be a great fit for industries that create parts of a lower geometric scale. Some examples are:

• Medical devices
• Glass industry
• Ceramic products
• Printed Circuit Boards (PCBs)
• Smaller electronics products

How Much Does a Small Waterjet Cutter Cost?

Small waterjet cutters can be acquired for around $30,000 to $50,000. Some models with added features can even go up to $100,000.

Medium Waterjet Machines

Medium waterjet machines have a size between small waterjet machines (4 x 4 feet) going up to 4 x 8 feet (1.2 x 2.4 m). These machines are design to cut a workpiece material with a large area. They sometimes come with multiple cutting heads to facilitate faster cutting. However, for optimal use of multiple cutting heads, it is better to go with larger options.

Advantages of Medium Waterjet Machines

• Larger Workpiece: Workshops can cut a larger area of material directly. This is the main reason they opt for medium waterjet machines.
• Higher Number of Pieces: Due to larger workpieces, more number of pieces can be obtained in a single setup. This can reduce the lead time for the operation.
• Easy Setup: Their setup, installation, and uninstallation is relatively easier compared to the goliaths that larger waterjets are.
• Movable: These machines are not as portable as small waterjet machines. However, they can still be moved around the workshop with some effort required.

Disadvantages of Medium Waterjet Machines

• Cost: Medium waterjets can cost a lot more than small waterjets. Very often, two small waterjets can come in the place of a single medium waterjet.
• Large Workpiece: The large workpiece is an advantage and a disadvantage. Loading of a large workpiece can be difficult. In many cases, the loading and unloading time negates the time saved in cutting more pieces.

Applications of Medium Waterjet Machines

Medium waterjet machines are used by niche industries that require fitting a particular size workpiece. Glass cutting is one of the main industries that utilize these machines. For instance, medium waterjets are used to make glass panels, partitions, and mirrors due to the particular size of the workpiece.

Cost of Medium Waterjet Machines

Medium waterjet machines can fall between $60,000 to $100,000. Going too high over it isn’t recommended, as multiple smaller waterjets or one large waterjet can be a better fit.

Large Waterjet Machines

Large waterjet machines can accommodate workpiece materials up to 8 x 16 feet (2 x 4 m). In many cases, this limit can be even more. Usually, these machines work with multiple machine heads. Large waterjets are common in industries that require high production numbers or very large structures.

Advantages of Large Waterjet Machines

• Workpiece Size: Large waterjets can load large sheets of material on the table. This provides the ability to create large frames for various industries.
• Production Rate: After a single setup, multiple heads can produce a large number of parts without unloading and reloading the material over and over.
• Cutting Speed: Multiple cutting heads exponentially increase the speed of the entire operation.

Disadvantages of Large Waterjet Machines

• Cost: Cost is the primary factor prohibiting people from buying a large waterjet machine. This is especially a deterrent for people new to this technology.
• Workpiece Setup: Large waterjet machines are designed to load a large workpiece. However, loading and unloading material of that size of workpiece is a herculean task. For instance, take the case of an 8 feet x 16 feet steel sheet just 0.1 inches thick. This sheet would weigh around 237 kg (522 lbs). This weight increases linearly as thickness increases.
• Secondary Operations: Waterjet machines are used for secondary finishing in many cases. However, large machines eliminate such usage. The proportions and setup requirements are unsuitable for secondary finishing applications.
• Tolerances: Large waterjets don’t provide as good tolerances as small waterjet machines. Therefore, for tolerance-specific applications, large sheets of material are cut down with a large waterjet and then machined with small waterjet cutters or laser shops.

Applications of Large Waterjet Machines

Large waterjet caters to two types of situations. The first situation involves high-volume manufacturing. Manufacturers cut a single part into many different pieces simultaneously by using a waterjet. The second situation involves areas where large-sized parts are required. A common example is the frames used in the aerospace and aircraft industries. Therefore, some common applications of large waterjets are:

• Aerospace Industry
• Packaging Industry
• Signage
• Oil fields
• Marine industry
• Transportation

Cost of Large Waterjet Machines

Large waterjet machines usually start at $100,000. The prices have a wide range and no upper ceiling. The main driving points are the pressure pump

Custom Waterjet Sizes

Custom waterjet sizes are those which are specifically designed for a particular application. These sizes generally apply when manufacturers want to incorporate waterjet cutting in their assembly line. The material moves through an automatic feeder mechanism to these machines and they process it as required. These machines usually don’t use standard material sizes.

Applications of Custom Waterjet Machines

Custom waterjets are mainly used where manufacturers want to speed their operation. These machines provide a seamless workflow without the need for loading or unloading material. These machines are also used in niche industries where standard sizes cannot fulfil the requirements. Common examples are:

• Food Cutting
• Carpet Industry
• Diaper cutting
• Eye Surgery
• Mining Applications
• Cardboard Box
• Paper Industry

How Much Does a Custom Waterjet Cost?

Custom waterjet machines can easily cost over $100,000. These machines cost more than standard machine sizes of comparable areas. This is because custom machines require a dedicated build and installation based on the requirements.

Does Machine Size Matter in Waterjet Cutting?

Yes, machine size indeed matters in waterjet cutting. You cannot just buy any machine and fit it into your workshop. The workshop should be able to accommodate the waterjet machine. Additionally, the size also affects other parameters like accuracy and cutting speed. Last but not the least, the size of the machine restricts the size of the workpiece that you can cut.

Are Big Waterjets Faster Than Small Waterjets?

Big waterjets with multiple cutting heads have a faster cutting speed than small waterjets. Additionally, they have fewer loading and unloading cycles. Therefore, the overall operation is exponentially faster. However, loading and unloading the large workpiece material can require some effort.

What Waterjet Size is Right For You?

Waterjet machines are not ‘one size fits all’. You need to buy the machine size that suits your requirements. Here are some factors that typical buyers should consider in this regard:

Production Environments

The first thing to consider is how much size your workshop can accommodate. You cannot fit a 4×8 feet machine in a workshop area of 4×6. Additionally, some clearing is required around the machine for the operator to move around during setup and unloading. Therefore, measure the space in your workshop that you can freely allocate to the waterjet machine.

Application

The next thing to consider is the industry in which you will use the waterjet cutter. Every industry has a particular size that is suitable. For instance, large or even medium waterjet machines are useless in the jewelry industry. Similarly, small waterjet machines cannot make large aircraft turbine blades.

Budget

Determine the budget that you can allocate to the machine. If the cost is restricted, buying a smaller waterjet cutter is a good idea. You can buy another small waterjet cutter after a period of time when the capital is available. You can opt for a large machine if you have the capital and want a high-production operation.

Where to Find a Waterjet Cutting Machine?

Techni Waterjet is the most reliable supplier of waterjet cutters worldwide. These machines are the industry standard when it comes to waterjet technology. Workshops in every sector use Techni Waterjet cutters in their assembly line.

There are many different models and size options in the catalog. You can choose the product fit for you. Additionally, every machine comes with integrated software, 24×7 customer support, and prompt availability of spare parts.

Endnotes

The size customization of waterjet technology is an attractive factor of this technology. Whether you have a small job shop or a large workshop for automobile modification, a waterjet machine is available for your requirements.

Get in touch with Techni Waterjet to learn more about these machines and find the ideal fit for your needs.

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This article will explore the application of waterjet cutting for the marine sector.

Waterjet Cutting

Waterjet cutting uses the extreme force of high-pressure water for cutting materials. Cutting is accomplished by eroding the particles of the workpiece. Waterjet cutting applies to a wide variety of materials like metals, non-metals, composites, paper, alloys, and more.

Cutting hard materials with a pure water jet is not fast enough. Therefore, abrasive materials are added to the water stream to speed up the process. The resulting method is called abrasive waterjet machining. Waterjet cutting is used in a variety of industries like the aerospace industry, defense industry, beverage industries, automotive industry, medical industry, etc.

What Marine Industry Materials Can Be Cut By a Waterjet?

Waterjet machines can virtually cut any type of material except diamonds. Therefore, it can achieve great results for all materials in the marine sector. The commonly encountered materials in the marine sector are:

Aluminum

Aluminum is the most used material not only in the marine industry but also in every other sector. Aluminum is used to craft large parts in the marine sector. Waterjet-cut aluminum makes deckhouses, hulls, ladders, railings, doors, window frames, and many other components.

Steel

Steel has exceptionally high strength and durability. This is why it is extensively used in marine applications. There are many grades of steel used for these purposes. All these grades can be easily cut with a waterjet cutter. In fact, water jet machining services can cut steel blocks 12 inches thick.

Stainless Steel

Stainless steel is preferred for many marine applications due to its corrosion resistance. Stainless steel also has good machinability so that the parts can be created cheaply. Waterjet cuts steel with a smooth edge for making fittings in ships and boating applications.

Titanium

Titanium is one of the strongest metals out there. It can resist corrosion even in extreme conditions of seawater. Deep sea equipment is encased in titanium shells for protection. These shells are made with waterjet cutting. Waterjet cutting can also make other titanium parts for seawater applications.

Alloys

The marine industry constantly uses alloys of copper-nickel, bronze, gunmetals, aluminum bronze, brass, silicon bronze, etc. The alloys combine properties like high physical strength, corrosion resistance, flexibility, and durability. These alloys often have poor machinability. Waterjet turns out to be a great way to cut these alloys.

Wood

Marine wood makes outdoor parts, stairs, furniture, support pillars, and many other components. Waterjet cuts multiple sheets of thick wood panels simultaneously. Unlike other cutting methods, using waterjet on wood doesn’t generate sawdust in the workplace.

Plastic

Plastics are used to make pipes, shafts, bearings, interior components, and many other things. Plastics are sensitive to heat. Therefore, conventional cutting processes can often cause thermal deformations in the material. However, waterjet cutting of plastic has no adverse effects.

Rubber

Rubber is used in marine applications for making fenders, bumpers, seals, and airtight containers. Rubber faces thermal deformations with hot-cutting processes similar to plastics. Therefore, water jet machining solutions are preferrable for marine rubber cutting.

Foam

Marine-grade foam is a versatile material. It replaces wood in many shipbuilding applications. It makes hulls, bulkheads, furniture, and interior parts. Foam cutting can be done with a  pure waterjet cutter without adding abrasives.

Fabrics

Fabrics are mainly used for ship interiors and sails in the case of sailboats. Fabric cutting can also be done with pure waterjet without using an abrasive. This makes it a very cheap and fast process. Additionally, fabric cut with waterjet has no burn marks, unlike the laser cutting service. This increases its appeal in interior applications.

Polyethylene

Polyethylene is a helpful material in the marine sector due to its waterproof and transparent nature. As such, it is used for making a protective box for electrical fittings. It also makes cable monitoring boxes, underwater visit boxes, and counter boxes.

Marine Applications of Water Jet Cutting

Waterjet has a wide range of applications in the marine sector. Some common applications of this technology are:

Marine Exteriors

Waterjet technology makes several parts for the outer body of ships, boats, yachts, and other marine vehicles. These parts include:

• Frames: Entire frame structures can be cut with a waterjet. Common materials include metals and wood.
• Door Panels: Waterjet cutters can cut door panels in a single pass. In fact, waterjet cut door panels are used in a variety of industries in addition to marine.
• Windscreen: Windows and windscreen are made using waterjet cutting technology. A common example is the windscreen seen on a yacht frame.

Marine Interiors

Waterjet cutting is preferred for interiors due to its high precision and no visible marks after cutting. Some of the interior parts that it creates are:

• Carpets: Carpets in ships and yachts are cut with a waterjet cutter.
• Seats: Seats are made with waterjet cut foams, leathers, and other textiles
• Dashboard: Dashboards are made with waterjet-cut plastics and composites

Construction

Waterjet cuts thick, hard materials for marine construction elements like:

• Support pillars
• Columns
• Hulls
• Deck
• Deckhouse

Miscellaneous Marine Parts

Many other components in marine applications are made using a water jet. These components are:

• O-rings
• Gasket cutting kits
• Flanges
• Brackets
• Clutch Plates
• Moldings
• Propeller
• Rudder
• Bow
• Keel

Advantages of Waterjet Cutting in the Marine Industry

Due to its unmatchable benefits, waterjet cutting is the preferred choice in various industries. Some of these benefits for the marine industry are:

• No Heat-affected Zones: Waterjet is a cold-cutting method. Therefore, there is no thermal deformation or burn marks on the material.
• Preserving Material Integrity: Thermal deformations alter the physical properties of materials. Waterjet cutting preserves these properties. This is essential in marine applications where accidents must be avoided at all costs.
• Speed: Waterjet cutting is a fast process. Additionally, it cuts multiple layers of material simultaneously. This leads to fast cutting.
• Accuracy: There is extreme precision involved in waterjet cutting. It can have tolerances as low as +/- 0.001″.
• Convenience: Waterjet can cut thick metal sheets with ease. This provides the convenience of moving large parts. Large parts can be cut into smaller parts and then assembled.
• Versatile: Waterjet cutters can work on a wide variety of materials. Therefore, a single machine can do multiple jobs.

Where to Find a CNC Waterjet Cutting Machine?

Techni Waterjet is the leading brand in the waterjet industry globally. Many prominent brands of all sectors use these machines in their assembly line. Techni Waterjet has a range of CNC waterjet cutting machines at different price points and with different features. All machines come with embedded software that can control the cutting process with the click of a button. Techni Waterjet is a top global supplier, so all spare machine replacement products are available promptly.

Conclusion

Marine industry professionals are switching to waterjet cutting due to its remarkable results. Quality waterjet solutions not only ease manufacturing, they also lead to complete customer satisfaction. Get in touch with Techni Waterjet to learn which waterjet machine will fit your requirements perfectly!

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