Since the force working on the workpiece is very small (under 1 kg for precision cuts and under 5 kg for average cutting) elaborate clamping devices can be dispensed with. Most users utilize simple light weights to hold their workpieces securely.
StM waterjet cutting systems with standard CNC equipment are no more difficult to program than any other cutting process. A standard CAM software simply converts DFX files into the cutting program; only the cutting speed must be adapted to changing materials. With the EasyCut software based on Windows programming is exceptionally easy! The finicky mental work is omitted. In other words projects can be programmed and cut quickly and accurately.
Foci of good carbide ceramics last around 100 hours. Foci of the highest carbide ceramics last around 30% longer than foci of other materials.
Such a focussing tube can achieve up to 150 cutting hours with an increase in diameter of 0.5 mm. Many of our customers utilize partially used foci for manufacturing parts where great accuracy is not required.
The supporting grates last for a good many cutting hours provided one does not always cut in the same place. The grids can be moved, exchanged and inverted same as with laser or plasma cutting systems.
The following minimum requirements for the water quality apply:
- pH value 7.0 – 8.5
- Carbonate hardness 20 – 60 ppm corresponds to 2 – 6 ° dH
- Calcium carbonate (Ca) 35 – 107 ppm
- Chloride content (Cl) ? 100 mg/l
- Infeed temperature for feed water 10 – 25 °C
- Electric conductivity at +25°C 450 µS/cm
- Filtrate dry residue 350 mg/l
- Free, dissolved chlorine 1 mg/l
- Feed water admission pressure 0.2 – 2.5 MPa
Deviations from these values lead to shorter service lives of the high-pressure seals of the pump and of the nozzles. Therefore, we recommend a water analysis and if necessary an appropriate water treatment.
This depends on the power of the high pressure pump and the water nozzle respectively.
High pressure pump:
- 19 kw: 1,9 l/min
- 37 kw: 3,8 l/min
- 45 kw: 4,6 l/min
- 75 kw: 7,6 l/min
- 0,1: 0,32 l/min
- 0,15: 0,71 l/min
- 0,2: 1,22 l/min
- 0,25: 1,87 l/min
- 0,3: 2,66 l/min
- 0,35: 3,57 l/min
- 0,4: 4,60 l/min
- 0,5: 6,82 l/min
The taper formed is a function of the cutting speed. The greatest possible taper is equal to the maximum kerf width on the surface of the material (e.g. 0,8 mm) and 0.0 mm on the underside of the material. When the cutting speed is reduced the taper is also reduced until one achieves parallel sides. The normal taper for precision cuts lies between 0.05 and 0.10 mm.
Laser cutting is an extremely productive process. Nevertheless the waterjet has several advantages over the laser:
- No thickness limitations
- No problems with reflective materials such as brass and aluminium
- No heat factor and therefore no burning and no changing of the material structure through heat
- With the waterjet heat-sensitive materials such as plastics, rubber or composite materials as well as glass, stone and extremely hard
- ceramics can be cut
- Changes of material: only the cutting speed is changed Neither gas nor optics must be switched
- Additional cutting heads can easily be mounted for an expanded production
- Maintenance of laser systems is specialized and more difficult to carry out
- Distance between nozzle and material is nowhere near as critical
- Waterjet systems are less capital intensive to purchase than lasers
EDM is extremely accurate but also extremely slow. It also needs an electrically conducting material and causes changing of the material structure through heat.
If one cuts through the edge of the material or holes or wants to manufacture blind holes and threads the abrasive waterjet is usually a lot faster, easier to program and also cheaper than a milling cutter.
This can be ascribed to the fact that we cut through in one pass and that we do not create any metal chips. Additionally should be noted that waste in complete form is worth more than in the form of chips.
Plasma cutting is a heat process. It introduces huge amounts of heat to the workpiece and leaves a heat-affected zone.
The surface created by a waterjet is generally superior. No edge is created on the underside of the material and consequently post-processing is not necessary. The abrasive waterjet is not subject to any limitation of depth of cut and several workspaces of a jet can lie in close proximity to each other.
The abrasive costs between € 280.00 and € 300.00 per ton ex works A-5531 Eben im Pongau.
The costs per hour start at € 19.00 for a small cutting head (nozzle: 0.15 mm / focus 0.6 mm) and extend to € 35.00 for a large cutting head (nozzle 0.35 mm/ focus 1.0 mm). In this amount all machine-relevant costs are included. Work, leasing and amortization must be added.
Generally between € 120.00 und € 220.00 per hour is charged for contract cutting on abrasive waterjet cutting systems.
It is severed. The safety equipment around the machine is therefore conscientiously designed. The operators of abrasive waterjet cutting systems are subject to stricter safety requirements than most machine operators in other industries.
Neither the water nor the garnet sand contain toxic substances. Consequently the water can be discharged into the drains after the suspended solids have settled or rather been filtered out. The abrasive can be disposed of as building waste. If the processed material is toxic or hazardous to health waste water and abrasive must be disposed of as hazardous waste!
The noise development when waterjet cutting is dependent upon the clearance of the free jet to the workpiece surface – i.e. the distance in which the waterjet travels through the air at supersonic speed. If one cuts under water the noise level sinks to under 75 dBA. If one cuts above water the noise level rises depending on the distance of the cutting head to the workpiece surface to as much as 105 dBA. In extreme cases the working area is totally covered.
Yes. Most customers use tap water. In front of the high-pressure pump the water must be filtered to 0.5 micrometres. Deionizing as well as osmotic systems are not recommended. Such systems clean the water too much – and waster which is too clean is extremely aggressive which leads to increased wear of the high-pressure system.