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Waterjet Basics. Main Office USA. Main Office Germany. Canada Montreal. Korea Seoul. Washington Olympia. China Shanghai. Illinois Chicago. India Mumbai. California Fresno. Sweden Ronneby. Oklahoma Tulsa. Poland Warszawa. Missouri Springfield. Mexico Mexico City. Georgia Atlanta.

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slide2

Main Office USA

Main Office Germany

CanadaMontreal

KoreaSeoul

WashingtonOlympia

ChinaShanghai

IllinoisChicago

IndiaMumbai

California Fresno

SwedenRonneby

OklahomaTulsa

PolandWarszawa

MissouriSpringfield

Mexico Mexico City

GeorgiaAtlanta

New JerseyShamong

BrazilSao Paulo

SpainMadrid

EnglandBirmingham

FranceParis

ItalyMilan

U.A.E.Dubai

The KMT Waterjet Network

what is waterjet cutting
What is Waterjet Cutting?
  • Erosion process of material
types of waterjets
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
What is an Orifice?
  • The primary component of the nozzle where the energy formation occurs
waterjet wj
Waterjet (WJ)?

Nozzle

Orifice

Waterjet

waterjet applications
Waterjet Applications
  • Food
  • Plastic
  • Foam
  • Paper
  • Gaskets
  • Rubber
abrasive waterjet awj
Abrasive Waterjet (AWJ)?

High Pressure Water

Abrasive

Jet

types of high pressure pumps
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
kmt intensifier family
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
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 SealRemoval
  • The KMT Pump has the lowest noise level
  • The KMT Pumps can be automatically balancing
horsepower hp
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
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
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
slide23

Pure Waterjet Turnkey System

Optional Water

Treatment System

HP INTENSIFIER

NOZZLE

ORIFICE

NOZZLE

ASSEMBLY

WATERJET

waterjet
Waterjet

TOPWORK CONSUMABLES

ON/OFF VALVE

HP WATER

HYDRAULIC OIL

LP WATER

Electric Motor & Hydraulic Power Pack

abrasive waterjet
Abrasive Waterjet

ON/OFF VALVE

TOPWORK CONSUMABLES

ABRASIVE FEEDER

HP WATER

HYD. OIL

LP WATER

NOZZLE

Electric Motor & Hydraulic Power Pack

abrasive1
Abrasive
  • What is abrasive?
  • What is mesh size?
  • What type of abrasive is common?
  • What is the pricing of abrasive?
  • Is abrasive recyclable?
garnet
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
Dynamic Waterjet vs. Standard Waterjet
  • Very Expensive
  • High Maintenance
  • Software issues
why waterjet
Why Waterjet?
  • Cold Cutting Process
    • No heat affected zone
    • No distortion or mechanical stresses
    • No dross or melting
    • No fumes, environmentally friendly
why waterjet1
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 waterjet2
Why Waterjet?
  • Versatile and Flexible Process
    • Metals & exotic materials such as Titanium
    • Highly reflective, thermal conductive materials & polished materials. Aluminum, Brass, Copper & Galvanized Steel
why waterjet3
Why Waterjet?
  • Versatile and Flexible Process
    • Marble, granite, ceramic tiles & glass
    • Fiberglass, composites & laminates
    • Etc….
key parameters
Key Parameters?
  • Operating pressure
  • Abrasive: flow rate, type & mesh size
  • Standoff distance
  • Cut rate; AWJ a single parameter process
awj avg operation cost
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
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
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
facts about waterjet
Facts about Waterjet?
  • Optimum cut rate is not maximum cut rate
  • Generally, AWJ is NOT linear process
  • AWJ is messy and aggressive process
xy tables mechanics
XY Tables: Mechanics
  • Belt Drives +/- 0.010”
  • Rack & Pinion +/- 0.005”
  • Ball Screw (Ground/Rolled) +/- 0.003”
  • Linear Drives (High Speed New Technology)
controllers
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
Motion Precision
  • Positional Accuracy
    • Per foot or per axis
    • Linear per single axis
    • Dynamic per dual axis
  • Repeatability
  • Tolerance (applied only to finished part)
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
feasibility questions1
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

Feasibility Questions
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

Application Limitations & Practical Considerations
non compelling application
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

Terminology
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