Waterjet Cutting: Process and Applications 2024

Waterjet cutting uses high-pressure water to slice through materials without heat. Here's what you need to know:

• Cuts almost anything from foam to 12-inch metal
• Precise (±0.005 inch tolerances)
• Doesn't alter material properties
• Used in aerospace, construction, and manufacturing
• Eco-friendly with water recycling

Key updates for 2024:

1. Multi-axis cutting tables for complex 3D shapes
2. Micro abrasive machines for hair-width precision
3. Advanced automated controls

Costs:

• Machines: $50,000 - $300,000
• Operating: $15 - $50 per hour

Waterjet cutting is transforming manufacturing with its precision, versatility, and eco-friendliness. It's ideal for applications needing exact cuts without heat damage.

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How Waterjet Cutting Works

Waterjet cutting slices through materials using super high-pressure water. Let's break down how it works and what's new in 2024.

The Basics

At its core, a waterjet cutter uses a pump that cranks up water pressure to 94,000 psi. That's intense. This water then shoots through a tiny hole, creating a stream as thin as a hair.

Here's what makes up a waterjet cutter:

1. A pump system that creates the high pressure
2. A machine with moving parts to guide the water
3. A control system to run the show

When the high-pressure water blasts through the nozzle, it moves faster than sound. This stream hits the material and cuts through it like a hot knife through butter.

Two Types: Pure Water and Abrasive

Waterjet cutters come in two flavors:

Pure Water Systems These are great for soft stuff. Think foam, rubber, and some plastics. They're perfect for food, fabrics, and things that need a gentle touch.

Abrasive Systems These are the heavy hitters. They mix tiny, hard particles with the water. This combo can cut through tough materials like metal and stone, even up to a foot thick.

Matt Riha from Southern Copper & Supply Company uses an abrasive system. He says:

"I've got copper that is hard as tool steel, and this water jet cuts it like it's butter."

What's New in 2024?

Waterjet cutting keeps getting better. Here's what's cool this year:

1. Multi-Axis Cutting Tables: These can make more complex cuts. Great for aerospace stuff.
2. Micro Abrasive Waterjet Machines: These are super precise. They can cut with accuracy down to a hair's width.
3. Water Recycling: Some companies now reuse their water. It's cheaper and better for the planet.
4. Smarter Controls: New waterjet cutters have fancy computer controls. You don't need to be an expert to use them.
5. Better Abrasive Delivery: The systems that add the cutting particles are more efficient now. Less waste, more cutting power.

These upgrades mean waterjet cutting is useful in more industries than ever. From cutting parts for planes to making intricate stone art, waterjet technology is making its mark.

As this tech keeps evolving, we'll likely see even more precise and versatile waterjet cutters in the future. It's an exciting time for this cutting-edge technology.

How the Process Works

Waterjet cutting uses ultra-high-pressure water to slice through materials with incredible precision. Let's break down how this tech works in 2024.

Creating High-Pressure Water

The heart of a waterjet system? A pump that cranks up water pressure to insane levels. We're talking 94,000 psi - that's 6,200 times the pressure in your car tires!

Here's the quick rundown:

1. Water enters the pump
2. Pump pressurizes it to extreme levels
3. Water's forced through a tiny jewel hole (0.1-0.4mm wide)
4. It shoots out at 1,000 m/s - 3x the speed of sound!

For tough stuff, they throw in some abrasive particles. Usually 80-mesh garnet, these get sucked into the water stream, creating a super-powered cutting slurry.

Control Systems

The brains behind the brawn? Sophisticated control systems. These digital wizards use CAD and machine tool control software to run the show.

They manage:

• Cutting head movement
• Water pressure and flow
• Abrasive flow (for abrasive systems)
• Material settings
• Cut specs

As Jet Edge, a big name in waterjets, puts it:

"Water jet control systems are the brains of the cutting tool. They tell the cutting tool and its components what to do and when to do it every step of the way through the cut."

These systems make sure every cut is spot-on, whether you're slicing foam or titanium.

Performance Measures

In waterjet cutting, performance is everything. Here's what matters:

Cutting Speed: Varies based on material. Example: A waterjet can cut 5mm aluminum at 38 cm per minute with a 0.014" nozzle.

Accuracy: Top systems can hit ±0.001" tolerances. That's EDM-level precision in some cases.

Surface Quality: Slower cuts = smoother finish, but less productive.

Check out this accuracy comparison:

Fun fact: Bump up the pressure from 60,000 to 90,000 PSI, and you'll see better speed, finish, and accuracy. But your wallet might feel it.

In 2024, waterjet cutting keeps pushing what's possible in manufacturing. It's versatile, precise, and eco-friendly - no wonder it's making waves from aerospace to art.

Materials and Limits

Waterjet cutting can slice through a ton of different materials. But it's not a one-size-fits-all solution. Let's break down what works and what doesn't.

What Can Waterjet Cutting Handle?

Waterjet cutting is like a Swiss Army knife for materials. It can cut:

• Metals (aluminum, titanium, stainless steel, you name it)
• Composites (Kevlar, fiberglass, carbon fiber)
• Stone (granite, marble, even delicate limestone)
• Plastics (acrylic, PVC)
• Soft stuff (foam, rubber, leather, vinyl)

Matt Riha from Southern Copper & Supply Company puts it this way:

"I've got copper that is hard as tool steel, and this water jet cuts it like it's butter."

The big win? No heat damage. Unlike lasers or plasma, waterjet doesn't mess with the material's properties.

What's Off-Limits?

Not everything plays nice with waterjet cutting:

• Tempered glass (it'll shatter)
• Diamonds (too tough)
• Some advanced ceramics
• Salt or caesium (they react with water)

How Smooth Is the Cut?

Pretty darn smooth. But there's a trade-off:

• Slow cuts = smoother finish
• Fast cuts = rougher finish

For metals, waterjet can hit ±0.001" tolerance. That's almost as good as EDM cutting.

Here's how it stacks up:

How Thick Can It Cut?

Waterjet can handle up to 12 inches thick. But for best results, stick to 3 inches or less.

The Australian Waterjet Cutting Team sums it up:

"Waterjet cutting doesn't produce HAZs, and it's why waterjet cutting produces silky, smooth edges and maintains the integrity of the material."

From precision parts to stone art, waterjet cutting is pushing boundaries. And it's only getting better.

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New Features and Updates

Waterjet cutting tech is getting better. Let's look at what's new in 2024 for automated controls and waste management.

Automated Controls

Automation is making waterjet cutting more accurate and efficient. Here's the scoop:

CNC Systems

The OSAI Series 10, a new CNC system from Tecnocut and OSAI, is a game-changer:

• It controls the cutting head better, making sheet metal work faster and more precise
• If the machine stops, you can start again right where you left off
• Pure water jet cutting is now up to 4x faster

Roberto Roagna from OSAI says:

"Higher precision in shorter execution times. It is an excellent result, reached thanks to the partnership that the two enterprises were able to create on that occasion."

Software Integration

FlashCut's CNC process shows how software can boost cutting precision:

• Better controls for corners, pump, and abrasive make part creation smoother
• The software automatically places lead-ins and nests parts
• You can choose from different pierce options (straight, wiggle, circular) for different materials

Five-Axis Cutting

Flex Machine Tools showed off their FlexJet Waterjet FL-0404 with:

• Igems CNC control and CAD/CAM software
• A tilting head for cutting complex shapes
• A camera for better positioning
• Tools for making cuts straighter and more accurate

These features help cut different materials more precisely and efficiently.

Waste Management

As waterjet cutting grows, so does the need to cut down on waste. Here's what's happening:

Water Recycling

WARDJet, Inc. has two new recycling systems:

• The WARD for big operations
• The WARD 2 for smaller shops (can dry up to 18,000 lbs per month)

Richard Ward from WARDJet says:

"We want companies to be able to own and operate and generate instant savings from the WARD 2. In effect, recycling is the same as securing another profitable contract, the profits being generated through savings instead of income."

Abrasive Recycling

More companies are recycling abrasive:

• Troy Cain's company pulls out 600-700 tons of abrasive from waterjet tanks each month
• Hypertherm launched a new abrasive recycling unit called EcoSift™

R. Randolph Rapple from Barton International notes:

"Today manufacturers look at total costs - the costs connected to something from the time it arrives at a facility to the day it is consumed or leaves the facility."

Filtration

Simple filtration methods are catching on:

• Settling tanks filter waterjet overflow water, keeping sewer lines clear
• Closed-loop systems reuse water and keep it clean

John Frosheiser from Custom Service and Design says:

"Because waterjet cutting doesn't leach material like EDM, installing a simple settling tank prior to the drain is the oldest and best form of filtration."

These new automated controls and waste management techniques are making waterjet cutting better than ever. As the tech keeps improving, we'll likely see even more efficient and eco-friendly solutions down the road.

Industry Uses

Waterjet cutting is changing the game in manufacturing. Let's look at how it's making a splash in aerospace and construction.

Aerospace Parts

Aerospace companies love waterjet cutting. Why? It's precise and works with tough materials without messing them up.

Cutting Complex Parts

Aerospace makers use waterjets to create tricky parts with tight specs. Thyssenkrupp Aerospace uses 8 OMAX waterjets to cut titanium and aluminum pieces up to 6 inches thick. Some cuts take hours!

Handling Composites

Waterjets are great for cutting composites like carbon fiber and Kevlar. OMAX Waterjet says:

"Abrasive waterjet has major advantages when cutting carbon fiber. No need to change tooling. No special considerations or restrictions due to heat buildup."

This makes it perfect for making light, strong aircraft parts.

Lots of Uses

Waterjet cutting isn't just for one or two things. It's used for:

• Turbine blades
• Engine parts
• Aircraft body panels
• Wing ribs and fuselages
• Brake parts
• Landing gear pieces

It can cut through stuff up to 12 inches thick, but most aerospace jobs stick to 3 inches or less.

Super Accurate

Aerospace needs high accuracy, and waterjet cutting delivers. It's as precise as ±0.001 inches, matching EDM cutting. It also leaves a smooth finish, often up to 0.8 µm Ra, so less extra work is needed.

Building and Design

Waterjet cutting is making waves in construction and design, especially for stone and glass work.

Cool Designs

Waterjet cutting lets architects get creative. It's used for:

• Fancy stone inlays
• Custom glass panels
• Decorative metal pieces
• Complex tile patterns

KMT Waterjet's tech is used a lot in architecture, letting designers make cool patterns and shapes that were hard or impossible before.

Stone Work

Waterjets are great for shaping stone up to 6 inches thick. They're used for:

• Granite and marble countertops
• Custom floor designs
• Decorative wall panels
• Sculptures

The tech cuts clean without cracking the stone.

Glass Cutting

For glass, waterjet cutting is precise without cracking or chipping. It's used for:

• Skylights
• Atriums
• Storefronts
• Stained glass fronts

The clean, smooth edges look good and are safer.

Eco-Friendly

Waterjet cutting is good for green building. It doesn't waste much and doesn't make harmful emissions, so it's great for eco-friendly projects.

As building and design keep changing, waterjet cutting is becoming a must-have tool. It lets people be creative while still being precise and efficient.

Choosing a Waterjet System

Picking the right waterjet cutting system can make or break your manufacturing process. Let's break down the tech specs and costs you need to know.

Technical Requirements

When shopping for a waterjet system, your specific cutting needs should drive your decision. Here's what to keep in mind:

What are you cutting? Waterjets can slice through everything from foam to titanium. Cutting harder stuff like stainless steel? You'll need an abrasive waterjet. For softer materials like vinyl, a water-only system might do the trick.

How thick is your material? While waterjets can handle up to 12 inches, most jobs stay under 3 inches. But don't let that limit you - Thyssenkrupp Aerospace uses OMAX waterjets to cut 6-inch thick titanium and aluminum for aerospace parts.

How precise do you need to be? Top-notch waterjet systems can match the precision of EDM cutting, hitting tolerances of ±0.001 inches. That's crucial for industries like aerospace where every millimeter counts.

How fast do you need to cut? Speed varies based on what you're cutting and how thick it is. For example, a waterjet can zip through 5mm aluminum at 38 cm per minute with a 0.014" nozzle.

Need automation? Look for systems with advanced CNC controls for complex cuts. The OSAI Series 10, used by Tecnocut, offers better cutting head control and can even resume cuts after stops.

A Jet Edge pro puts it this way: "A system should be designed around today's need with an eye on the future." In other words, think about what you need now AND what you might need down the road.

Price Factors

Waterjet systems aren't cheap, but they're a game-changer for many manufacturers. Here's the price breakdown:

Upfront Costs:

• Water-only CNC waterjet: $50,000 - $100,000
• 2-axis abrasive system: $100,000 - $200,000
• High-end models: $200,000+
• Custom-built machines: $200,000 - $400,000

Running Costs: Expect to shell out $15 to $50 per hour to keep your waterjet running. This covers utilities, consumables, operator time, programming, and maintenance.

Want to keep those costs down? Here are some tips:

• Use efficient pumps
• Streamline your programming
• Set up for lights-out operation
• Install an Abrasive Removal System
• Opt for an efficient cutting head

Don't just look at the price tag - consider the total cost of ownership. A pricier system might save you money in the long run through better efficiency and lower operating costs.

Take XYZ Manufacturing, for example. This mid-sized industrial company compared machines across different price points. They ended up going for a premium machine, despite the higher upfront cost, because it offered a big boost in performance and capabilities.

On a budget? Used equipment might be the way to go. Southern Fabricating Machinery Sales says used waterjet cutting machines typically cost about half as much as new ones. But buyer beware - if you're going used, make sure to thoroughly check out the intensifier, nozzle, electrical cabinet, maintenance records, and control system.

Summary

Waterjet cutting has changed the game in manufacturing. It's a cold cutting process that uses high-pressure water, sometimes mixed with abrasives, to slice through materials without heat.

Here's why it's so cool:

• It can cut almost anything, from soft foam to 12-inch thick metal.
• It's super precise, with tolerances as tight as ±0.005 inches.
• It doesn't mess with the material's structure because there's no heat involved.

In aerospace, companies are using waterjets to cut thick titanium and aluminum parts. It's also great for working with composites like carbon fiber, which is perfect for making lightweight, strong aircraft parts.

Builders love it too. They're using waterjet cutting to create fancy patterns in stone and glass up to 6 inches thick. It's opening up a whole new world of design possibilities.

And get this: it's eco-friendly. The systems recycle water and create minimal waste. That's a big deal in today's world where everyone's trying to be more sustainable.

The tech keeps getting better. In 2024, we've seen:

1. Multi-axis cutting tables

These bad boys can create complex 3D shapes, which is a game-changer for aerospace.

2. Micro abrasive waterjet machines

These can cut with hair-width precision. Talk about intricate!

3. Automated controls

New systems like the OSAI Series 10 give better control over the cutting head and can even resume cuts after stops.

Now, these machines aren't cheap. You're looking at $50,000 to $300,000 to get started. But many manufacturers say it's worth it in the long run. Operating costs are usually between $15 to $50 per hour.

Dr. Norman Franz, who patented this tech back in 1971, would be blown away by today's systems. They're operating at pressures up to 94,000 psi, which is just insane.

Looking ahead, waterjet cutting is set to keep playing a big role in manufacturing. It's precise, efficient, and green - exactly what modern manufacturing needs. As we keep pushing the boundaries of what we can make, this tech is going to be right there at the forefront.

FAQs

What are the applications of water jet cutting?

Water jet cutting is a versatile technology used across many industries:

Aerospace: It cuts complex parts from titanium, aluminum, and composites. Thyssenkrupp Aerospace uses OMAX waterjets to slice through 6-inch thick titanium and aluminum for aircraft parts.

Construction: It creates intricate designs in stone, glass, and metal. KMT Waterjet's tech often shows up in custom floor designs, decorative wall panels, and skylights.

Manufacturing: It's great for cutting precision parts from metals, plastics, and rubber. It's a go-to for prototyping and small-batch production.

Food industry: It slices soft foods like cakes, fruits, and vegetables without heat damage or contamination.

Textiles: It cuts fabric, foam, and other soft materials without fraying, which is perfect for fashion and automotive industries.

What type of application is suitable for waterjet cutting?

Waterjet cutting shines in applications that need:

1. Precision: These systems can hit tolerances as tight as ±0.001 inches. That's why aerospace loves them.

2. No heat damage: Unlike laser or plasma cutting, waterjet doesn't create heat. This keeps material properties intact, which is crucial for heat-sensitive materials.

3. Versatility: From soft foam to 12-inch thick metal, waterjet can handle it all. As Matt Riha from Southern Copper & Supply Company puts it, "I've got copper that is hard as tool steel, and this water jet cuts it like it's butter."

4. Complex shapes: With fancy CNC controls like the OSAI Series 10, these systems can create intricate 2D and 3D shapes. Perfect for architectural designs or custom manufacturing.

5. Eco-friendly cutting: These systems produce minimal waste and can recycle water. It's a win for eco-conscious manufacturing.