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Waterjet cutting machines
In metal industries, various machines such as waterjet cutting machines, plasma cutting machines, laser cutting machines and hydraulic guillotine sheet cutting machines are used for cutting sheets. Depending on the conditions in which they are used, Each type of cutting machine can be more efficient than the others in different conditions. Plasma cutting is considered by some to be the best option for sheet cutting; It is a misconception of working conditions that is sometimes overlooked. Some people believe that plasma cutting is the best option for cutting sheets. However, it is a misconception of working conditions, which is sometimes totally overlooked.
Water jet cutting machines are not only widely used for cutting metal sheets but they are also used for cutting wood, ceramics, stone, leather, conductive parts, semiconductor and non-conductive parts. The fact is that lack of information about cutting machines increases the possibility of making mistakes by selecting improper machines. Therefore, it is recommended that we increase our knowledge in this area before purchasing cutting machines. How these machines work, what their strengths and weaknesses are, what their advantages and disadvantages compared to other cutting machines are and the like can increase our knowledge and possibly reduce mistakes in the selection process.
A water jet cutting machine consists of several main parts including a very powerful pump, a cutting head, a catch tank, a garnet hopper and a controller system. Before installing these machines, the ground under the machine is leveled and a concrete layer of about 15 to 20 cm is made. The tank and the table are connected to the ground by a number of screws and the garnet tank is installed next to the machine. It should be noted that the dimensions of the tables for waterjet cutting machines can be different from a machine to another or made according to the customer's requests. However, those which are manufactured with a length of 6 meters and a width of 3 meters are normally used for various purposes, making this size the standard one as defined by some manufacturers.
The source of water supply can be domestic or industrial water pipes, but the water should be passed through filters that separate water impurities because the salts or pollutants in water can reduce the life of machine parts or sometimes cause problems in the cutting process. The water free of any salts enters the intensifier pump. This pump can increase the pressure up to 70,000 bar. It is worth noting that there are also less powerful water jet cutting machines which are manufactured and are used for cutting materials such as leather, fabric, plastic, rubber, wood and fiber.
These machines use less water and, in terms of structure and automation, they are simpler, smaller and cheaper than metal sheet cutting machines. Garnet is not used in these machines, especially in those which are used for cutting food material in food industries. Therefore, not all waterjet devices are equipped with a garnet system, but those used in the metal industry are equipped with a garnet tank. The garnet tank has a sensor that tells the operator, by sending a beep, to charge the tank whenever the garnet is running low. This tank is also equipped with a proportion valve that can increase or decrease the garnet output. These garnets are moved toward the device by an air compressor.
The protective shield, which is installed in many waterjet machines, can prevent the nozzle from accidentally colliding with the part. Of course, the head is also equipped with another shield, called the blast shield, which prevents the returned water from colliding when the head is inclined and wants to make an angled cut. This shield acts like an umbrella during angular cuts and is considered as a consumable part that sometimes needs to be replaced. Because the pressure of water is extremely high at the time of cutting, and this pressure, together with garnet, can easily widen the mouth of the nozzle, manufacturers of waterjets - especially very strong waterjets - use a perforated diamond in the nozzle through which the water passes with a high pressure.
Advantages of Waterjet Cutter
The quality of the cut edges in waterjet is very high. Edge quality and accuracy are a function of speed, pressure, nozzle size and abrasive flow rate. In fact, water jets can perform chipping and cutting operations at the same time, which reduces production costs.
Waterjet cutting is very efficient and cost effective. Waterjet can cut thick parts such as aluminum, composites, composites, hardened steels up to 25 mm thick.
Due to the lack of heat in the waterjet cutting process, there is no HAZ area and there is no information about the complexity of the parts, the hardening of the edges, the color change and the change in the mechanical properties of the cut area.li>
Waterjet cutting machines can offer cuts between 0.038 and 0.2 mm thick. Therefore, they are used in sensitive industries to produce high precision parts
Waterjet cutting machines do not need to change cutting tools to create different cuts. The water jet machine can cut all kinds of parts into different shapes with the same nozzle and abrasives.
Waterjet cutting machines have high flexibility in cutting. So if your product can't be reached by Waterjet, it probably won't be removed at all.
On some cutting machines, the cutting shape is simple and without special complexity. Therefore, to achieve three-dimensional and complex shapes, the piece must be placed at different angles. However, in waterjet cutting, this is not necessary and the desired shape is easily created.
The reduction in production costs is very tangible in the use of waterjet cutting machine. Low energy consumption, high cutting speed, no waste of raw materials, cutting in one step and the need for low maintenance are cost-reducing factors and It is economical to cut with a waterjet machine.
Disadvantages of waterjet cutting machine
Lasers are faster and more efficient at cutting thin parts than waterjet machines.
Waterjet is unrivaled and very powerful for the cutting process, but it is not suitable for engraving and designing because it does not have the necessary precision to create the design.
The cutting nozzle head in the waterjet is larger than the laser. This increases the accuracy of laser cutting compared to waterjet. If the details of the work are important to you, we suggest that in addition to consulting with expert consultants, you compare the same work from both laser cutting and waterjet.
Which one should we choose? Waterjet cutting machine or laser cutting machine?
Both cutters can be used to make simple cuts on thin or small pieces. In this case, the choice of each of them depends on the type of production and the level of your expectations. But if high-complexity cuts and thicker sections, deeper and three-dimensional cuts are considered, the result changes drastically towards waterjet cutting. Click for more information.
Application of waterjet cutting machines
The capability and efficiency of waterjet cutting machines along with its many advantages have caused them to be considered in different industries. Including:
Rubber and Composite Industries
Using industrial waterjets for other purposes
Some people think that industrial waterjets are used only for cutting metal sheets, but it must be mentioned that they are used not only for cutting other parts such as wood, ceramics, leather, plastic, stone, glass and some other stuff, they are also used for removing rust, cleaning, removing paint from parts, scraping worn-out machineries, and degreasing. These machines act like shot blast machines to remove rust or paint.
Since there are new nozzles which are used in such waterjet machines (especially the portable ones), these machines can also perform finishing operations (which are considered as operations after the roughing and before the polishing processes). Use industrial waterjets in the finishing process is very economical as well.
Moreover, due to the possibility of increasing or decreasing water pressure and using special nozzles, the speed of the finishing process is very high. Another application of waterjets is in creating grooves on sheets or parts, and this happens when we reduce the water pressure. The lower the water pressure, the lower the depth of the groove will be.
Therefore, waterjets can not only perform cutting operations satisfactorily but they can also create holes and seams in sheets or parts. Because water pressure can move small lightweight pieces during the cutting process - especially during angled cutting - it is strongly recommended that we secure those tiny lightweight parts to the support ribs using fixtures or magnetic clamps. Vibrations or small displacements can have a negative effect on cutting and drilling operations, in which case the desired size will not be achieved.
Buy waterjet cutting machines
When buying water jet cutters, you should have enough information about how it works and its technical characteristics. Here are some common questions that buyers of waterjet cutters face
Some frequent questions the customers ask our experts at FactorNeed:
What is garnet and should garnet be used for cutting sheets?
Can used garnets be recycled and reused in the cutting process?
How thick can metal sheets be to be cut by waterjet machines?
How much water and garnet is consumed per minute?
How accurate are waterjet cutting machines compared to laser and plasma cutting machines?
How fast are waterjet cutting machines compared to laser and plasma cutting machines?
Which brands or companies are famous manufacturing waterjet cutting machines?
Can the water source be the same as the building’s pipe?
When should I use garnet?
How much garnet does a waterjet cutting machine use to cut sheets?
When the plasma cutting machine was invented, it would work only with water and had a very simple system including a high-pressure pump and a nozzle. After a while, they found that if another substance, such as fine sandpaper grains called garnet, was added to the water, the depth and speed of cutting would increase. These garnets, which are natural minerals, could hit the piece harder and cause more erosion. It should be noted that a good garnet should have four characteristics including hardness, stiffness, density and special shape. In addition, one of the best suppliers of garnets for waterjet cutting machines is Barton, and the other is Shapegarnet Co., which offers garnets in different weights such as 25 kg packages.
No. This is not sensible for several reasons. A) When these garnets hit the surface of the workpiece at a high speed, they lose their original shape. B) When the garnets collide with the surface of the part, very small particles are separated from the part, which enter the tank together with the garnet. Therefore, we will have both the used garnets and the small particles of the part in the tank. Apparently, it would not be cost effective to get them separated, even if we do not consider the deformation of garnets.
Powerful waterjet cutting machines can cut sheets up to 300 mm in thickness. But in this case, the speed of the machine should be very lowered, which will need a relatively long time to cut sheets in these thicknesses. However, waterjet cutting machines will be more suitable for cutting sheets that have a thickness from 1 mm to a maximum of 100 mm.
The amount of water which is used depends on the amount of pressure and the amount of garnet which is used. In other words, the higher the pressure, the more water will be consumed, and the more garnet we use, the less water will be consumed. Each machine normally consumes between 15 and 20 liters of water per minute.
If we want to compare waterjet cutting machine with other cutting machines in terms of accuracy and speed, laser cutting machines have the highest cutting accuracy. After laser cutting machines, waterjet cutting machines and then plasma cutting machines will have the most accuracy.
If we consider the sheet thickness ranging between 1.5 to 35 mm, plasma cutting machines have the highest cutting speed, then we will have laser cutting machines, and finally there are waterjet cutting machines.
As mentioned before, waterjet cutting machines are used in different industries and the best can be different in each industry. For example, in the food industry, the Dutch company Gegebv is excellent and famous for cutting vegetables, but in the metal industry or other industries, other manufacturers from different countries are famous. Since the focus in FactorNeed in on metal industries, we list the following manufacturers that are famous in the field of metal industries:
There will be no problem if the output of the pipe is more than 20 liters per minute, because waterjet cutting machines typically consume about 18 liters of water per minute.
In simple words, whenever you can cut pieces with industrial scissors, there is no need to use garnet, but if the thickness and stiffness of the piece is high and the material is not part of the food industry, you can use garnet. As mentioned earlier, garnet increases the cutting speed and the penetration. Waterjet cutting machines are able to cut parts even without garnets.
Although the use of garnet can be an option selected by the operator and considering the fact that material, cutting speed and sheet thickness are considered as important parameters, a waterjet cutting machine typically consumes between 300 and 450 grams of garnet per minute.
What is the price of a waterjet cutting machine?
The price is determined based on many parameters such as the brand, the country of origin, the cutting power, the automation level of the cutting steps, the machine’s options, and the size of the machine. To get the price, you can send an email to the manufacturer - whose email address is mentioned on the website of FactorNeed - and directly ask the manufacturer for the price. To get the price, it is necessary to inform the manufacturer of the specifications of the parts you want to cut, such as the minimum thickness, the maximum thickness, the length, the width, the material, and the tolerance.
Manufacturers of waterjet cutting machines
In recent years, waterjet has been developed as one of the most widely used types of cutting methods. Waterjet machines use pressurized water at very high speeds to cut various materials accurately. The waterjet machine is capable of cutting most types of metals and some types of glass and ceramics. Waterjet cutting was first used as a technique for the rapid rinsing of rocks and loose coal from mining projects in New Zealand and South Africa in the 19th century. In the 1970s, the United States combined 40,000 bar cutting devices with waterjets and special nozzles. Later, industrial designers discovered that by adding sand to water, destructive power of waterjet cutting would be increased.
Choosing a right manufacturer
In general, before choosing a machine manufacturer, it is better to determine some topics like "what type of cutting operation Specify the material to be made "and also" how much material is to be produced ". Some manufacturers specialize in prototypes or disposables, while others regularly produce thousands or sometimes millions of pieces. Companies should also increase their information and technical knowledge about the details of the material and the best way to jet cut them as much as possible.
Waterjet Sweden company
Waterjet Sweden develops, designs and manufactures a variety of waterjet machines worldwide, and the company's machines meet all customer requirements for a waterjet machine. The products of this company are divided into 4 main categories:
- Standard category:
- Selection category:
- Micro category:
- Special category:
The machines of this category are designed for simple cutting operations. However, various options have been included in the machines of this category, which completely meet the needs of small workshops and light operations. Machines in this category can be cut in 2 dimensions with pressure of 4000 or 6000 bar. Also, some of these machines are equipped with two torches for cutting operations. These machines are made in different sizes such as 1 × 1m, 1 × 2m, 3 × 2m and 6 × 2m.
This category includes customers' customized machines that are based on their design in order to meet customer requirements. Depending on the customer's order, these machines can be equipped with features such as 3D cutting, 5-axis machine, using several torches, etc. Also, the tables of these devices can be made in different sizes and have the ability to cut parts up to 60 degrees for miter cuts.
Micro machine can be used to cut small pieces. The micro machine has a very high cutting accuracy and the material loss in them is very low. This machine is made in the size of 1×1 meters and with a pressure equals to 4000 bar, and has got the ability to cut sheets up to 100 mm thick.
Each project is unique and machine systems are developed in close collaboration with the customer. Machines in this category are designed and manufactured for the very special needs of customers.
Flow is one of the most advanced and well-equipped manufacturers of waterjet devices located in the United States and exclusively works in design and production of waterjet machines. Flow has always produced its machines in different sizes and with different applications and has classified them as Mach100, Mach200, Mach300, Mach400, Mach500, Mach600, Mach700 and Nanojet. as we move from the Mach100 to the Mach700, the capabilities and sizes of the machines become higher and larger. Nanojet is also a versatile waterjet device that is a pioneer in waterjet design in the world and delivers cuts with the highest accuracy and the lowest noise. The Nanojet waterjet device is located in a completely enclosed area to maximize the level of safety of the machine.
Omax Company is one of the best manufacturers of waterjet cutting machines in the world. In addition to producing water jet cutting machines, the company also produces their equipment and accessories. The video below shows one of Omax's waterjet cutting machines.
More information about WaterJet Machines
Differences between waterjet, laser and plasma cutting machines
Imagine now that you are buying a sheet metal cutting machine and you know that water jet cutting machines and plasma cutting machines as well as slip cutting machines have the ability to cut sheets well. If you want to make the best choice, you must have enough information about each. Know the strengths and weaknesses of each. Otherwise you may make a mistake and regret your purchase after a while.Read More