waterjet basics

KMT US Inc. - KMT Waterjet

Waterjet Basics


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What is Waterjet Cutting?

Erosion process of material


Types of Waterjets?

Abrasive Waterjet (AWJ): involves the entrainment of abrasive

particles into the high pressure water jet

Waterjet (WJ): using only high pressure water jet energy with no

additives


What is an Orifice?

The primary component of the nozzle where the energy formation

occurs


Waterjet (WJ)?

Orifice

Waterjet

Nozzle


• Plastic

• Foam

• Paper

• Rubber

• Food

• Gaskets

Waterjet Applications


Waterjet Applications


Abrasive Waterjet (AWJ)?

Abrasive

Jet

High Pressure Water


How AWJ Works?


Abrasive Waterjet Application


Types of High Pressure Pumps?

Intensifier Pump– More expensive and highly reliable– Less maintenance required and fewer components– Easier to work on and to maintain

Direct Drive Pump– High maintenance frequencies and time consuming – Cheaper alternative for a reason– Limited high pressure supply


Direct Drive Pump / Mechanical Pump


Intensifier Pump


Intensifier Topwork?


KMT Intensifier Family

SL-V 15, 30R, 50R, 75R, 100R, 150R & 200R hp

Multiple shift operation

EXCLUSIVE Hard Seal End Cap design

Ergonomically designed for ease of maintenance

Standard Allen Bradley display panel


KMT vs. FLOW Pump

The KMT Pump has an 8" stroke while FLOW has a 4" inch stroke

The KMT pump is the only unit that uses Metal-to-Metal HSEC

The KMT Pump uses Single topwork concept on all models

The KMT pump uses independent bolts in the Hydraulic Cylinder

The KMT Pump is the easiest pump to maintain

The KMT Pump allows Leak-Free Plunger & Hydraulic Seal Removal

The KMT Pump has the lowest noise level

The KMT Pumps can be automatically balancing


KMT Intensifier Components


Horsepower (HP)?

Energy is Horsepower. The Higher the horsepower:

The faster the cutting rates

The greater the number of Nozzles

The thicker the material you can cut


What Does 50 HP Stand for?

50 HP is the electric motor size. A 50 HP unit is the rating of the

high pressure pump that is capable of providing a maximum water

capacity of 1 GPM

The HP of the pump determines power, number of orifices, and

respective sizes


Energy Creation?

Water generated from pump is focused into a small component

called “Orifice” to generate the high pressure water Jet that travels

around Mach 2 or Mach 3


Pure Waterjet Turnkey System

Optional WaterTreatment SystemHP INTENSIFIER

NOZZLEASSEMBLY

ORIFICE

WATERJET

NOZZLE


Waterjet

HP WATER

HYDRAULIC OIL

LP WATER

TOPWORK CONSUMABLESON/OFF VALVE

Electric Motor & Hydraulic Power Pack


Abrasive Waterjet

ABRASIVE FEEDER

NOZZLE

ON/OFF VALVETOPWORK CONSUMABLES

Electric Motor & Hydraulic Power Pack

HP WATER

HYD. OIL

LP WATER


Abrasive


Abrasive Consumption

Nozzle SizeOptimal

Abrasive RateMaximum

Abrasive Rate

Practical Abrasive Mesh

Size

7/21 0.3 lb/min 0.4 lb/min120, 150, 180,

200

10/30

9/300.75 lb/min 1.0 lb/min 80, 100, 120

14/43

13/431.3 lb/min 1.5 lb/min 50, 65, 80


Abrasive

What is abrasive?

What is mesh size?

What type of abrasive is common?

What is the pricing of abrasive?

Is abrasive recyclable?


Garnet

Hard Rock, abrasive that is mined in a quarry– Faster cutting because of sharper, more angular edges.– High Purity garnet, less dust and clogging issues.– Used in for precision and best edge quality

Alluvial, abrasive that is found on the bottom of river beds– Cost control solution– Less precise– Generally slower cut speeds and rougher edge


Dynamic Waterjet vs. Standard Waterjet

Very Expensive

High Maintenance

Software issues


Sizing


Orifice Size Vs Horsepower, 60,000 PSI

Orifice Size 15 HP 30 HP 50 HP 60 HP 75 HP 100 HP 150 HP 200 HP

0.005 2 4 7 8 10 14 21 28

0.007 1 2 3 4 5 7 10 14

0.009 1 2 2 3 4 6 8

0.010 1 1 2 2 3 5 7

0.011 1 1 2 2 4 5

0.012 1 1 1 2 3 4

0.013 1 1 1 2 3 4

0.014 1 1 1 2 3

0.015 1 1 2 3

0.016 1 1 2 2

0.017 1 1 2

0.018 1 1 2

0.019 1 1 1

0.020 1 1

0.021 1 1

0.022 1 1


Horsepower & Pump Capacity?

55 ksi Operating Pressure

Orifice 30 HP 50 HP 75 HP 100 HP

0.007” 2 4 6 8

0.010” 1 2 3 4

0.014” - 1 - 2


Waterjet Advantages


Why Waterjet?

Cold Cutting Process

No heat affected zone

No distortion or mechanical stresses

No dross or melting

No fumes, environmentally friendly


Why Waterjet?

No special tooling, minimal or no setup

Minimal kerf width & maximum material utilization

Rapid prototyping, programming

Minimal or no burr & quality surface finish


Why Waterjet?

Versatile and Flexible Process

Metals & exotic materials such as Titanium

Highly reflective, thermal conductive materials & polished materials. Aluminum, Brass, Copper & Galvanized Steel


Titanium Alloy..


Brass.. SS.. Aluminum..


Why Waterjet?

Versatile and Flexible Process

Marble, granite, ceramic tiles & glass

Fiberglass, composites & laminates

Etc….


Stone.. Glass..


Waterjet Parameters


Key Parameters?

Operating pressure

Abrasive: flow rate, type & mesh size

Standoff distance

Cut rate; AWJ a single parameter process


AWJ: Avg. Operation Cost?

The hourly cost to run an AWJ machine starts commonly at $17 plus per single nozzle

2/3 of cost is in abrasive

1/3 of cost is in rest of consumables: utilities, nozzle, and intensifier unit


Facts: Waterjet Tolerances?

Taper control works best with thick metals

AWJ practical tolerances, +/- 0.003” plus

Tight tolerances are expensive to hold

Critical: Motion equipment, work envelope


Edge Quality

Coarse Medium Fine Extra Fine

Edge quality is a function of speed, pressure, nozzle size and abrasive flow rate

Striation marks are the bend in the stream


Edge Quality


Facts about Waterjet?

Optimum cut rate is not maximum cut rate

Generally, AWJ is NOT linear process

AWJ is messy and aggressive process


Waterjet vs. Others

AWJ EDM Laser Plasma Gas

Thickness + + + - + + + +

Cut Rate - - - + + + + +

Surface Finish + + + + + - - -

Heat Affected Zone + + + + - - - -

Environment Safety + + - - - - - - - -

Material Flexibility + + - + - - - -

Secondary Operation + + + + - - -

Operation Cost - + - + + +

Capital Investment 100% 60% 200% 80% 40%


Motion Equipment


XY Tables: Mechanics

Belt Drives +/- 0.010”

Rack & Pinion +/- 0.005”

Ball Screw (Ground/Rolled) +/- 0.003”

Linear Drives (High Speed New Technology)


Controllers

Dedicated

– Allen Bradley, Fanuc, Mitsubishi, Num….– Expensive, reliable, repeatable, closed architecture 40 – 50k

PC Based: Open architecture & inexpensive 10-20k

– Open architecture & inexpensive 10 - 20k– Dedicated to Manufacturer


Motion Precision

Positional Accuracy– Per foot or per axis– Linear per single axis– Dynamic per dual axis

Repeatability

Tolerance (applied only to finished part)


XY Motion Configuration


XYZ Motion Configuration


Waterjet Practicalities


Feasibility Questions

Material WJ or AWJ

Existing Method & Process

Justification & Why WJ

Primary/Secondary Operation

Cycle Time Concern

Programming Method

Parts Small vs. Large

Material Stacking

Sheet Metals

Loading/Unloading

Production, Dedicated or Job Shop

# of Shifts


Feasibility Questions

Pump Capacity, # Cutting Heads

Pump Location

Water Quality

Abrasive Reclamation

Zero Discharge Closed Loop System

Part Tolerance

Sheet Sizes

Tank/Bed Type

Abrasive Type & Mesh Size

Site Planning


Application Limitations & Practical Considerations

Line Speed

Material Support & Handling

Automation & Fixtures

Moisture Retention

Abrasive Migration

Staining

Extrusions

Castings

Wafers & Shim Stock

Ceramics & Carbides

Gumminess

Microscopic Abrasive Adhesion


Non-Compelling Application

Extrusions

Layered non-homogeneous material

Tempered Glass

Tubes


Terminology

Burr

Delamination

Frosting

Taper

Fraying

Frost Piercing

Kerf

Striations

Rooster Tail/ Stream Lag

Splash Back

Corners & Curves

Practical Thickness & Limitations


Supply Water Quality


Water Quality Standards

CATEGORYMINIMU

M BETTER BEST

ALKALINITY (MG/L) 50 25 10

CALCIUM (MG/L) 25 5 0.5

IRON (AS Fe) (MG/L) 0.2 0.1 0.01

MAGNESIUM (AS Mg) (MG/L) 0.5 0.1 0.1

MANGANESE (AS Mn) (MG/L) 0.1 0.1 0.1

pH (SU) 6.5-8.5 6.5-8.5 6.5-8.5

SILICA (MG/L) 15 10 1

TDS (MG/L) *** 200 100 5

HARDNESS (AS CaCO3) (MG/L) 25 15 1


End

waterjet basics

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