Advanced
Trimester 2 2009/2010
Assignment Title:
Waterjet Cutting
Lecturer name:
Students Name:
Beyond cost cutting, the waterjet process is recognized as the most versatile and
fastest growing process in the world. Waterjets are used in high production
applications across the globe. They compliment other technologies such as milling,
laser, EDM, plasma and routers. No noxious gases or liquids are used in waterjet
cutting, and waterjets do not create hazardous materials or vapors. No heat effected
zones or mechanical stresses are left on a waterjet cut surface. It is truly a versatile,
productive, cold cutting process.
The waterjet has shown that it can do things that other technologies simply cannot.
From cutting whisper thin details in stone, glass and metals; to rapid hole drilling of
titanium; to cutting of food, to the killing of pathogens in beverages and dips, the
waterjet has proven itself unique.
The water circuit consists of the inlet water filters, booster pump, intensifier, and
shock attenuator. Ordinary tap water is filtered by the inlet water filtration system –
usually comprising of a 1 and a 0.45 micron cartridge filter. The filtered water then
travels to the booster pump, where the inlet water pressure is maintained at
approximately 90 psi – ensuring the intensifier is never “starved for water.” The
filtered water is then sent to the intensifier pump and pressurized to up to 60,000 psi.
Before the water leaves the pump unit to travel through the plumbing to the cutting
head, it first passes through the shock attenuator. This large vessel dampens the
pressure fluctuations to ensure the water exiting the cutting head is steady and
consistent. Without the attenuator, the water stream would visibly and audibly pulse,
leaving marks on the material being cut. [1]
The hydraulic circuit consists of an electric motor (25 to 200 HP), hydraulic pump, oil
reservoir, manifold, and piston biscuit/plunger. The electric motor powers the
hydraulic pump. The hydraulic pump pulls oil from the reservoir and pressurizes it to
3,000 psi. This pressurized oil is sent to the manifold where manifold’s valves create
the stroking action of the intensifier by sending hydraulic oil to one side of the
biscuit/plunger assembly, or the other. The intensifier is a reciprocating pump, in that
the biscuit/plunger assembly reciprocates back and forth, delivering high-pressure
water out one side of the intensifier while low-pressure water fills the other side. The
hydraulic oil is then cooled during the return back to the reservoir.The advanced
technology in the pump is found in the intensifier. As mentioned briefly in the
description of the water circuit, the intensifier pressurizes the filtered tap water to up
to 60,000 psi. [3]
Intensifier pumps utilize the “intensification principle.”
If Force = 20, Area = 20, then Pressure = 1. If we hold the Force constant and greatly
reduce the Area, the Pressure will go UP. For example, reduce the Area from 20 down
to 1, the Pressure now goes up from 1 to 20. In the sketch below, the small arrows
denote the 3,000 psi of oil pressure pushing against a biscuit face that has 20 times
more area than the face of the plunger. The intensification ratio, therefore, is 20:1. [1]
In the illustration below, the biscuit and plungers are in the green section and outlined
in red. The biscuit contains the small arrow suggesting movement to the left. The two
water plungers extend from either side of the biscuit. High-pressure water is delivered
out the left side while low-pressure water refills the right. At the end of travel, the
biscuit/plunger assembly sequence is reversed [1]
Sophisticated check valves ensure the low pressure and high-pressure water is only
allowed to travel one direction. The high-pressure cylinders and end caps that encase
the plunger and biscuit assembly are specially designed to withstand the enormous
force and the constant fatigue.The entire unit is designed for long life, while also
designed to fail in a safe way. Waterjet systems fail in a gradual, rather than
instantaneous way. The seals and connections begin to leak slowly through specially
designed weep holes. The operator or maintenance person can see a drip escaping
from a weep hole. The location of the drip and the amount of water indicate when
maintenance should be performed. Usually, the maintenance person can schedule the
periodic maintenance of seals and check valves out 1 to 2 weeks into the future by
simply monitoring the gradual weeping. Warning and shutdown sensors also cover the
pumping unit to further safeguard against pump damage. [1]
2. Types of Waterjets
· Very thin stream (0.004 to 0.010 inch in diameter is the common range)
· Extremely detailed geometry
· Very little material loss due to cutting
· Non-heat cutting
· Cut very thick
· Cut very thin
· Usually cuts very quickly
· Able to cut soft, light materials (e.g., fiberglass insulation up to 24” thick)
· Extremely low cutting forces
· Simple fixturing
· 24 hours per day operation [2]
As you may recall from an earlier section of this document, the basic waterjet
process involves water flowing from a pump, through plumbing, and out a cutting
head.In waterjet cutting, the material removal process can be described as a
supersonic erosion process. It is not pressure, but stream velocity that tears away
microscopic pieces or grains of material. Pressure and velocity are two distinct
forms of energy. But how is the pump’s water pressure converted to this other form
of energy, water velocity? The answer lies in a tiny jewel. A jewel is affixed to the
end of the plumbing tubing. The jewel has a tiny hole in it. The pressurized water
passes through this tiny opening changing the pressure to velocity. At approximately
40,000 psi the resulting stream that passes out of the orifice is traveling at Mach 2.
And at 60,000 psi the speed is over Mach 3. Pure waterjet orifice diameter ranges
from 0.004 to 0.010 inch for typical cutting. When waterblasting concrete with a
nozzle traversing back and forth on a tractor, a single large orifice of up to 1/10 th of
an inch is often used.
The abrasive waterjet differs from the pure waterjet in just a few ways. In pure
waterjet, the supersonic stream erodes the material. In the abrasive waterjet, the
waterjet stream accelerates abrasive particles and those particles, not the water, erode
the material. The abrasive waterjet is hundreds, if not thousands of times more
powerful than a pure waterjet. Both the waterjet and the abrasive waterjet have their
place. Where the pure waterjet cuts soft materials, the abrasive waterjet cuts hard
materials, such as metals, stone, composites and ceramics. Abrasive waterjets using
standard parameters can cut materials with hardness up to and slightly beyond
aluminum oxide ceramic (often called alumina, AD 99.9).
Within every abrasive waterjet is a pure waterjet. Abrasive is added after the pure
waterjet stream is created. Then the abrasive particles are accelerated, like a bullet in a
rifle, down the mixing tube.
The abrasive used in abrasive waterjet cutting is hard sand that is specially screened
and sized. The most common abrasive is garnet. Garnet is hard, tough and
inexpensive. Like the pink colored sandpaper found at the hardware store, different
mesh sizes are used for different jobs:
120 Mesh – produces smooth surface
80 Mesh – most common, general purpose
50 Mesh – cuts a little faster than 80, with slightly rougher surface
The mixing tube acts like a rifle barrel to accelerate the abrasive particles. They, like
the orifice, come in many different sizes and replacement life. Mixing tubes are
approximately 3 inches long, ¼ inch in diameter, and have internal diameters ranging
from 0.020 to 0.060 inch, with the most common being 0.040 inch. Although the
abrasive waterjet machine typically is considered simple to operate and ‘bullet proof,’
the mixing tube does require operator attention. A major technological advancement
in waterjet was the invention of truly long-life mixing tubes. Unfortunately, the longer
life tubes are far more brittle than their predecessors, tungsten carbide tubes. If the
cutting head comes in contact with clamps, weights, or the target material the tube
may be broken. Broken tubes cannot be repaired. Today’s most advanced systems
incorporate collision detection to spare the mixing tube.
The standoff distance between the mixing tube and the target material is typically
0.010 to 0.200 inch. Larger standoff (greater than 0.080 inch) can cause a frosting to
appear atop the cut edge of the part. Many waterjet systems reduce or eliminate this
frosting by cutting under water or using other techniques.
The consumable items in an abrasive waterjet are the water, abrasive, orifice (usually
Ruby) and mixing tube. The abrasive and mixing tube are exclusive to the abrasive
waterjet. The other consumables are also found in the pure waterjet.
Waterjets are fast, flexible, reasonably precise, and in the last few years have become
friendly and easy to use. They use the technology of high-pressure water being forced
through a small hole (typically called the "orifice" or "jewel") to concentrate an
extreme amount of energy in a small area. The restriction of the tiny orifice creates
high pressure and a high-velocity beam, much like putting your finger over the end of
a garden hose.Pure waterjets use the beam of water exiting the orifice to cut soft
material like diapers, candy bars, and thin soft wood, but are not effective for cutting
harder materials.
Typical design of a pure waterjet nozzle A diagram of an abrasivejet nozzle
The inlet water for a pure waterjet is pressurized between 20,000 and 60,000 Pounds
Per Square Inch (PSI) (1300 to 6200 bar). This is forced through a tiny hole in the
jewel, which is typically 0.007" to 0.020" in diameter (0.18 to 0.4 mm). This creates a
very high-velocity, very thin beam of water (which is why some people refer to
waterjets as "water lasers") traveling as close to the speed of sound (about 600 mph or
960 km/hr).
An abrasivejet starts out the same as a pure waterjet. As the thin stream of water
leaves the jewel, however, abrasive is added to the the stream and mixed. The high-
velocity water exiting the jewel creates a vacuum which pulls abrasive from the
abrasive line, which then mixes with the water in the mixing tube. The beam of water
accelerates abrasive particles to speeds fast enough to cut through much harder
materials.
The cutting action of an abrasivejet is two-fold. The force of the water and abrasive
erodes the material, even if the jet is stationary (which is how the material is initially
pierced). The cutting action is greatly enhanced if the abrasivejet stream is moved
across the material and the ideal speed of movement depends on a variety of factors,
including the material, the shape of the part, the water pressure and the type of
abrasive. Controlling the speed of the abrasivejet nozzle is crucial to efficient and
economical machining. [4]
4. Advantages of waterjet
"If you need a machine and don't buy it, then you will ultimately find you have paid for it but don't have it" -
Henry Ford.
There is a reason that waterjet machining has rapidly grown in popularity since the
mid-1990's. Actually there are a number of reasons, listed below, but they mostly
come down to "versatility." A waterjet is a versatile and flexible machining tool. You
can cut a wide variety of material efficiently and cost-effectively and can create a
wide variety of parts. [4]
Because waterjets cut using water and abrasive, they can work with a wide variety of
materials. These materials include:Aluminium, brass, copper, Pre-hardened steel,
Mild steel, Exotic materials such as titanium, inconel and hastalloy, 304 stainless steel,
brittle materials such as ceramic, quartz, stone, laminated materials, flammable
materials [4]
One of the few materials that cannot be cut with a waterjet is tempered glass.
4.2 Fast setup and programming
With waterjet machining, a flat piece of material is placed on a table and a cutting
head moves across the material (although in some custom systems, the material moves
past a fixed head). This simplicity means that it's fast and easy to change materials
and that no tool changes are required. All materials use the same cutting head, so there
is no need to program tool changes or physically qualify multiple tools.
Waterjet machining does not introduce any stresses into the material.
What little heat is generated by the waterjet is absorbed by the water and carried into
the catch tank. The material itself experiences almost no change in temperature during
machining. During piercing 2" (5 cm) thick steel, temperatures may get as high as
120° F (50° C), but otherwise machining is done at room temperature.
The result is that there is no heat affected zone (HAZ) on the material. The absence of
a HAZ means you can machine without hardening the material, generating poisonous
fumes, recasting, or warping. You can also machine parts that have already been heat
treated. [4]
Obviously, you don't put any body parts in front of a waterjet machining head while it
is on. Anything that can cut through 2" steel will make short work of flesh and bone.
Aside from this, however, waterjets are very safe. A leak in a high-pressure water
system tends to result in a rapid drop in pressure to safe levels. Water itself is safe and
non-explosive and the garnet abrasive is also inert and non-toxic. One of the largest
hazards is cuts from the sharp edges of material created by the waterjet. [4]
Control of the waterjet head is complicated and requires careful calculation to get the
proper speed that will give the best result. This means that the system needs to be
controlled by a computer, which means that the user-interface for the system can be
simplified and made friendlier. Modern systems are designed the same way as many
other computerized CAD systems and are quickly learned. [4]
4.8 Environmentally friendly
As long as you are not machining a material that is hazardous, the spent abrasive and
waste material become suitable for land fill. The garnet abrasive is inert and can be
disposed of with your other trash.If you are machining lots of lead or other hazardous
materials, you will still need to dispose of your waste appropriately, and recycle your
water. Keep in mind, however, that very little metal is actually removed in the cutting
process. This keeps the environmental impact relatively low, even if you do machine
the occasional hazardous material.In most areas, excess water is simply drained to the
sewer. In some areas, water treatment may be necessary prior to draining to sewer. In
a few areas, a "closed loop" system that recycles the water may be required.The
pumps do use a considerable amount of electricity, though, so there is some additional
environmental (and cost) impact due to this. [4]
Start holes are only required for materials that are difficult or impossible to pierce. A
few poorly bonded laminates can fall into this category, in which case pre-drilling or
other special methods may be used.
The amount of material removed by the waterjet stream is typically about 0.02" (0.5
mm) wide, meaning that very little material is removed. When you are working with
expensive material (such as titanium) or hazardous material (such as lead), this can be
a significant benefit. It also means that you can get more parts from a given sheet of
material.When machining or roughing out expensive materials such as titanium, your
scrap still has value. This is because you get chunks, not chips. [4]
Waterjets have a number of advantages over lasers. In many respects, however, the
two tools are complementary and many machine shops own both of them.
1. Waterjets can machine reflective materials that lasers cannot, such as copper
and aluminum. Waterjets cut a wide range of material with no changes in
setup required. Also, materials which are heat-sensitive can be cut using
waterjets.
2. Waterjet cutting does not heat your part. There is no heat-affected zone (HAZ)
or thermal distortion, which can occur with lasers. Waterjets do not change the
properties of the material.
3. Abrasivejets typically use garnet as the abrasive material. Garnet is a non-
reactive mineral that is biologically inert. The only issue with waterjets is
when you are cutting a material that is potentially hazardous (such as lead),
since small pieces of the material will be abraded and mix in with the spent
garnet.
4. There are no noxious fumes, such as vaporized metal, and no risk of fires. The
distance between the end of the waterjet nozzle and the material is typically
very small, although caution is needed when the waterjet nozzle is raised.
5. The cost of a waterjet machine is generally much lower than that of a laser.
For the price of a laser, you can purchase several waterjet machining centers.
The expansion formula of the distance between water molecules [6,7,8] rn= r0×η
nrn denotes the distance between water molecules after expansion, r0 denotes the
original distance
between water molecules before expansion, r0 = 0.4 [7] nm; ηn for the expansion of
multiples. According to last picture and calculation we can know r1 <r2 <r3 <r4,and r
controls particle size for r denotes the size of the place where water jet fail to impact
of microbe cells, as for the control of the production of biological particles broken the
basis of data. Now, living examples of diameters of biologic particles obtained by the
machine were illustrated.
Structure of the spray nozzle was presented in last picture, Water jet in left and right
spray pipes where the interval between the water molecules r0, r0=0.4 nm, was
interfused 10%-12% of microbe cells and given strong pressure P which was strong
enough to crush microbe cell. The size of obtained biologic particles was calculated as
follows:
With the practical measuring values:
d=1.2mm, d1=2.4mm, d2=4.8mm,d3=9.6mm, d4=19.2mm. The interval between the
water molecules at the position d1 may be calculated: r1, By the same way we can
know, r2=6.4nm, r3=25.6nm, r4=102.4nm.
When ηn =1,rn =0.4 nm, the size of particle is under nano-grade. When ηn
=2.6~250,
rn =1~100 nm, the particles are just nanograde. When ηn﹥250,rn﹥100 nm, the
particles are upper nano-grade. [6]
9. Water jet can cutting alloy steels with out change the properties.
Look at the diagram, minimum heat for transforms ferrite to austenite is around 730
digree. And maximum heat that waterjet creat is around 120 digree. It means waterjet
can cutting alloy steels with out change the properties. [10]
Low alloy steels contain alloying elements as Ni, Mn, Cr, Si, Mo, Nb, Cu. The
percentage of all alloying elements does not exceed 5%. [9]
9.2 High alloy steels can cutting with waterjet
High alloy steels contain alloying elements as Ni, Mn, Cr, Mo, Nb, W, V, Cu. The
total percentage of all alloying elements is higher than 5%. [9]
Stainless steels are high alloy steels. Their chromium content is at least 12%. for
example if cut stainless steels with laser cutting machines then chromium will be
burn.
Refrences
[1]
http://www.flowcorp.com/uploadedFiles/WJ%20Overview%20White%20Paper.
pdf
[2] http://www.flowcorp.com/waterjet-resources.cfm?id=336
[3] http://www.edmtodaymagazine.com/TechTipsMyJun09.pdf
[4]
http://waterjets.org/index.php?option=com_content&task=category§ionid=4
&id=46&Itemid=53
[5] http://www.hydrocut.org/abrasive_waterjet_cutting.htm
[6] http://www.iop.org/EJ/article/1742-
6596/188/1/012036/jpconf9_188_012036.pdf?request-id=2425819c-20f5-4c5f-
9ab1-ed92e942cb21
[7]
http://docs.google.com/viewer?a=v&q=cache:3ur7FaoWpNUJ:https://app.mfg.c
om/servlet/mfg.files.DownloadFilePublic%3FfileId%3D89617%26fileTypeId%3
D2%26noRefresh%3D1+Laser+cutting+involves+using+a+laser+focused+on+m
aterial+to+melt,+burn,+or+vaporize+the+material.+The+laser+can+be+a+gas+la
ser+(such+as+CO2)&hl=en&gl=my&sig=AHIEtbTxNTCk121RmSEl3c50g2lV
8OVKGg
[8] http://lyle.smu.edu/rcam/research/waterjet/par2.html
[10] https://online.tu-
graz.ac.at/tug_online/voe_main2.getVollText?pDocumentNr=63649