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Waterjet Basics

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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Waterjet Basics

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  1. Waterjet Basics

  2. 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

  3. What is Waterjet Cutting? • Erosion process of material

  4. 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

  5. What is an Orifice? • The primary component of the nozzle where the energy formation occurs

  6. Waterjet (WJ)? Nozzle Orifice Waterjet

  7. Waterjet Applications • Food • Plastic • Foam • Paper • Gaskets • Rubber

  8. Waterjet Applications

  9. Abrasive Waterjet (AWJ)? High Pressure Water Abrasive Jet

  10. How AWJ Works?

  11. Abrasive Waterjet Application

  12. 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

  13. Direct Drive Pump / Mechanical Pump

  14. Intensifier Pump

  15. Intensifier Topwork?

  16. 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

  17. 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

  18. KMT Intensifier Components

  19. KMT Intensifier Components

  20. 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

  21. 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

  22. 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

  23. Pure Waterjet Turnkey System Optional Water Treatment System HP INTENSIFIER NOZZLE ORIFICE NOZZLE ASSEMBLY WATERJET

  24. Waterjet TOPWORK CONSUMABLES ON/OFF VALVE HP WATER HYDRAULIC OIL LP WATER Electric Motor & Hydraulic Power Pack

  25. Abrasive Waterjet ON/OFF VALVE TOPWORK CONSUMABLES ABRASIVE FEEDER HP WATER HYD. OIL LP WATER NOZZLE Electric Motor & Hydraulic Power Pack

  26. Abrasive

  27. Abrasive Consumption

  28. Abrasive • What is abrasive? • What is mesh size? • What type of abrasive is common? • What is the pricing of abrasive? • Is abrasive recyclable?

  29. 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

  30. Dynamic Waterjet vs. Standard Waterjet • Very Expensive • High Maintenance • Software issues

  31. Sizing

  32. Orifice Size Vs Horsepower, 60,000 PSI

  33. Horsepower & Pump Capacity?

  34. Waterjet Advantages

  35. Why Waterjet? • Cold Cutting Process • No heat affected zone • No distortion or mechanical stresses • No dross or melting • No fumes, environmentally friendly

  36. 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

  37. Why Waterjet? • Versatile and Flexible Process • Metals & exotic materials such as Titanium • Highly reflective, thermal conductive materials & polished materials. Aluminum, Brass, Copper & Galvanized Steel

  38. Titanium Alloy..

  39. Brass.. SS.. Aluminum..

  40. Why Waterjet? • Versatile and Flexible Process • Marble, granite, ceramic tiles & glass • Fiberglass, composites & laminates • Etc….

  41. Stone.. Glass..

  42. Waterjet Parameters

  43. Key Parameters? • Operating pressure • Abrasive: flow rate, type & mesh size • Standoff distance • Cut rate; AWJ a single parameter process

  44. 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

  45. 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

  46. 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

  47. Edge Quality

  48. Edge Quality

  49. Facts about Waterjet? • Optimum cut rate is not maximum cut rate • Generally, AWJ is NOT linear process • AWJ is messy and aggressive process

  50. Waterjet vs. Others

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