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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.
4. Advantages of waterjet
Waterjet machining does not introduce any stresses into the material.
"If you need a machine and don't buy it,
then you will ultimately find you have paid 4.5 Almost no heat generated on your part
for it but don't have it" - Henry Ford.
What little heat is generated by the waterjet is absorbed by the water
There is a reason that waterjet and carried into the catch tank. The material itself experiences almost
machining has rapidly grown in no change in temperature during machining. During piercing 2" (5
popularity since the mid-1990's. cm) thick steel, temperatures may get as high as 120° F (50° C), but
Actually there are a number of otherwise machining is done at room temperature.
reasons, listed below, but they
mostly come down to The result is that there is no heat affected zone (HAZ) on the
"versatility." A waterjet is a material. The absence of a HAZ means you can machine without
versatile and flexible machining hardening the material, generating poisonous fumes, recasting, or
tool. You can cut a wide variety warping. You can also machine parts that have already been heat
of material efficiently and cost- treated.
effectively and can create a
wide variety of parts. 4.6 Are very safe
4.1 Cut virtually any material 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
Because waterjets cut using will make short work of flesh and bone. Aside from this, however,
water and abrasive, they can waterjets are very safe. A leak in a high-pressure water system tends
work with a wide variety of to result in a rapid drop in pressure to safe levels. Water itself is safe
materials. These materials and non-explosive and the garnet abrasive is also inert and non-toxic.
include:Aluminium, brass, One of the largest hazards is cuts from the sharp edges of material
copper, Pre-hardened steel, created by the waterjet.
Mild steel, Exotic materials such
as titanium, inconel and 4.7 Modern systems are now very easy to learn
hastalloy, 304 stainless steel,
brittle materials such as ceramic, Control of the waterjet head is complicated and requires careful
quartz, stone, laminated calculation to get the proper speed that will give the best result. This
materials, flammable materials means that the system needs to be controlled by a computer, which
means that the user-interface for the system can be simplified and
One of the few materials that made friendlier. Modern systems are designed the same way as many
cannot be cut with a waterjet is other computerized CAD systems and are quickly learned.
tempered glass.
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.
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.
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.
6. With lasers, the material needs to be relatively uniform. In particular, when cutting over uneven
surfaces, the laser can lose its focus and cutting power. A waterjet will retain much of its cutting
power over uneven material. Although the material may deflect the cutting stream, it typically has a
negligible effect.
7. How thick you can cut is a function of how long you are willing to wait. Waterjets easily handle 2"
(5cm) steel and 3" (7.6 cm). Although some people have used waterjets at thicknesses of up to 10"
(25 cm) in steel, it is difficult to maintain precision in materials thicker than 2" (5 cm). Lasers seem
to have a maximum practical cutting thickness of 0.5" (12 mm) to 0.75" (19 mm).
8. Maintenance on a waterjet is simpler than that of a laser
9. Waterjets are computer controlled, so that the operator does not have to be highly skilled and
trained.
10. Material cut by waterjets have a fine, sand-blasted surface because of the way the material was
abraded, which makes it easier to make a high-quality weld. Material cut by laser tends to have a
rougher, scaly edge, which may require additional machining operations to clean up.
rn denotes the distance between water molecules
after expansion, r0 denotes the original distance
6. A Research and design the nozzle of water jet
Crusher [4,5,6,7,8,9,10,11,15]
between water molecules before expansion, r0 = 0.4
The nozzle is the core engine of the water jet crusher [7] nm; ηn for the expansion of multiples.
and can launch a fan-shaped water jet and control According to last picture and calculation we can
the density of water jet (that is, the distance between know r1 <r2 <r3 <r4,and r controls particle size for r
water molecules). If the needs of smaller particles, denotes the size of the place where water jet fail to
the distance between water molecules should be impact of microbe cells, as for the control of the
smaller. If the biological needs of larger particles, production of biological particles broken the basis of
the distance between water molecules should be data. Now, living examples of diameters of biologic
bigger, with direct proportion of its function: y = f particles obtained by the machine were illustrated.
(x). The fan-shape water jet is fired through nozzles. 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
In this picture, we can see from d4, d3, d2, d1 the molecules at the position d1 may be calculated: r1,
water density is different. We summarised the By the same way we can know, r2=6.4nm,
distance between water molecules expansion r3=25.6nm, r4=102.4nm.
multiplier formulation[6,7,8] in accordance with the
relevant principles of mathematics.the expansion of
multiples ηn where dn,
pump mechanism. The problem of water quality has Firs step in the process of making decision of hether
been recognized and addressed by the vendors of water preparation system is needed or not is to
the equipment. As a result it has been found analyze a sample of local water on certified
necessary to set water quality standards in order to laboratory and make a treatment recommendation.
operate high-pressure water jet cutting systems Water should be lean top water. Although the water
effectively. Many localities do not have water passes though a filtering system before it reaches the
sources that satisfy these requirements. It has been pump, the cleaner the water the less frequently you
found that if the water supply is inadequate then the will need to service the filter. If you are using a
result is equipment malfunction. A solution was separate water filtering system, you should make
found through water preparation system. sure you service the filters at the recommended
intervals. The water should not be hard or contain
large quantities of dissolved iron and silica. These
materials cause problems in both the pump and the
nozzle. 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 micrometer cartridge filter. For these
reasons the original 5 micrometer fiber cartridge
filter fitted to the first machine has not always been
adequate to protect the pump and jet delivery
system, even though, in that installation, no erosion
of the seals and shafts had occurred after the first six
months of operation. In these circumstances, slight
changes in water chemistry can significantly affect
There are several ways to treat the water prior to the erosion resistance of some of the components
use. The simplest is a water softening treatment within the pump mechanism.
similar to that used in the household. The second
method is reverse osmosis, which consists of passing
the water through a very fine membrane which
filters out the impurities on the molecular level. And
the third is de-ionizing circuit.
Water quality required for an Ingersoll-Rand Water jet Cutting System
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.
Low alloy steels contain alloying elements as Ni, Mn, Cr, Si, Mo, Nb, Cu. The percentage of all
alloying elements does not exceed 5%.
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%.
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.