the ultimate guide to waterjet precision cutting
TRANSCRIPT
The Ultimate Guide to Waterjet Precision Cutting
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Industry professionals employ a variety of cutting processes, each of which offers unique characteristics that make it suitable for different manufacturing applications. Some of the most commonly used methods are waterjet cutting, plasma cutting, and laser cutting. Choosing between the three options can be difficult as they vary in regard to initial investment and operating costs, efficiency, and effectiveness. As such, it’s worth researching the differences between them before making a final decision.
In this eBook, we outline the advantages and disadvantages of each precision cutting process. Additionally, we discuss the industrial applications of waterjet cutting and the step-by-step waterjet cutting process employed at Metal Craft Spinning & Stamping.
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Waterjet Cutting vs. Plasma Cutting vs. Laser Cutting
The waterjet cutting process uses highly pressurized streams of water—sometimes combined with abrasives such as garnet or aluminum oxide—to cut materials into the desired shape and size. Compared to mechanical or thermal cutting methods, it offers a number of advantages regarding cutting effectiveness and efficiency, such as:
Advantages and Disadvantages of Waterjet Cutting
Broader material suitability. The waterjet cutting process is suitable for use with a broad selection of materials, including metals, plastics, foams, and wood. Additionally, it can process materials that are difficult to cut with other cutting methods (e.g., thick or multi-layer substrates) without needing starting holes.
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Mechanical cutting processes—e.g., sawing—employ the use of cutting tools to produce the desired cuts on the workpiece. In contrast, the waterjet cutting, plasma cutting, and laser cutting processes rely on non-contact cutting mechanisms (e.g., high-pressure water streams, superheated ionized gas, or high-powered light beams). This difference allows them to achieve greater control, precision, and accuracy than many conventional cutting methods. Below we outline the key advantages and disadvantages of the three processes.
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Greater material utilization-to-waste generation ratio. Waterjet cutters produce kerfs with smaller widths, which allows machine operators to place part designs closer together on the workpiece and, consequently, enables more material to be used and less material to be wasted during operations.
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Lower risk of thermal warping. Waterjet cutting is a cold cutting process. As such, it generates smaller amounts of heat than other cutting methods, which lowers the risk of thermal damage and distortion for the workpiece.
Higher precision and accuracy. Waterjet cutting operations create parts to net-shape or near-net-shape that often require little to no secondary processing to meet the project specifications.
Smaller fixturing requirements. The fixturing requirements for waterjet cutting are minimal, which lower the amount of time spent setting up operations and the amount of money invested in them.
Better operator safety. Waterjet cutters do not produce hazardous gas—which can adversely impact the health of the machine operator—when cutting into materials.
Faster cutting speeds. Waterjet cutting offers faster cutting times than mechanical cutting processes, including for thicker materials.
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While the waterjet cutting process benefits manufacturing operations in many ways, it is not suitable for every project. Some of the primary disadvantages of the process include:
` Noise levels during operations are high unless the piece is cut underwater
` Abrasive dust generated during operations can coat the machine area and damage unprotected sensitive components
` Costs for abrasive cutting media (e.g., garnet) are high (up to and exceeding $12/hour)
` Disposal of waste material and water can pose an environmental issue
` Focusing nozzle in the cutting heat can wear over time which can affect cut quality and accuracy
` High part accuracy (down to ±0.008 inch)
` Fast processing speeds (200 IPM for 16 gauge mild steel and 45 IPM for 1-inch thick mild steel)
` Quick learning curve for machine operators
` Simple maintenance requirements
` Low investment costs (compared to laser cutting)
` Broad part size capacities
Advantages and Disadvantages of Plasma Cutting
The plasma cutting process—also sometimes referred to as plasma arc cutting or plasma jet cutting—utilizes superheated ionized gas (i.e., plasma) funneled through a plasma cutting torch to cut electrically conductive materials. It serves as a cost-effective cutting option for a wide range of metals. Some of the other advantages it offers include:
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Similar to all manufacturing processes, plasma cutting has its limits. Some of the main disadvantages of the process are as follows:
The laser cutting process relies on a focused and high-powered beam of light (i.e., laser) to cut a variety of substrates, including metals, plastics, glass, paper, and wood. Some of the capabilities of the process include:
Advantages and Disadvantages of Laser Cutting
` Lower cutting accuracy and quality than waterjet cutting and laser cutting
` Larger heat affected zone (HAZ)
` Broader tooling requirements as the cutting head needs to be changed for each metal and thickness. The consumables need to be replaced regularly
` Smaller material flexibility than laser cutting for simultaneous processing of thin and thick substrates
` Higher risk of microfracturing on certain materials
` Greater amounts of hazardous fumes generated during operations
` Suitability for metal and non-metal materials, including simultaneous processing of thin and thick substrates
` Cutting accuracy of ±.002 inch or better
` Cutting speeds of 1000 IPM or better for thin materials
` Cut edge squareness of less than one degree
` Hole diameters less than one-half the thickness of the material
` Smaller HAZ than plasma cutting
` Accommodation of automation technology
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Compared to waterjet cutting and plasma cutting, the laser cutting process comes with significantly higher investment and operating costs, including in regard to the machine and the cutting assist gas (~$15/hour). This price point can eliminate this process as a cutting option for many projects. Other disadvantages include:
` Difficulty processing reflective materials (the laser can reflect back and damage the focusing lens)
` Potential for microfracturing on certain materials
` Inconsistency in cutting performance depending on material quality and condition
` Safety concerns regarding exposing machine operators to high-powered lasers
Industrial Applications of Waterjet CuttingIndustry professionals employ waterjet cutting to cut a wide range of materials, from metals and plastics to stone and tile. The process’s versatility, combined with its precision, accuracy, and efficiency, makes it well-suited for use in various manufacturing operations. Some of the industries that regularly utilize waterjet cutting for the production of their parts and products, include:
• Aerospace
• Architecture
• Biotechnology
• Chemical processing
• Food processing
• Marine
• Mechanical
• Packaging
• Pharmaceutical
• Vacuum
• Welding
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2D and 3D Waterjet Cutting Systems
Early waterjet cutting systems were designed for use with very thin materials like paper. As such, their use in mainstream manufacturing applications was limited. Nowadays, they are employed by both small job shops and large manufacturing companies for the fabrication of a wide range of parts and products in various materials and thicknesses.
Two of the most significant developments in waterjet cutting technology are the introduction of multi-head functionality and the ability to cut three-dimensional parts. While three-axis and four-axis systems may accommodate many manufacturing needs, five-axis and six-axis models offer opportunities for the production of even more complex and intricate pieces.
The latter types eliminate the need for flat workpieces, allowing industry professionals to cut intricate, non-uniform, and asymmetrical materials.
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Metal Craft’s Step-by-Step Waterjet Cutting ProcessAt Metal Craft Spinning and Stamping, we follow all industry best practices when manufacturing any component using waterjet cutting. By working closely with the customer, we determine the necessary part and production specifications. With these in hand, we then move on to the waterjet cutting operation.
A waterjet cutter works by directing extremely high-pressure streams of water—with or without abrasive—at the material. Achieving this function requires significant pressure, which it generates through the use of a hydraulic intensifier pump. The pump pressurizes water pulled into the system through the low-pressure water input and inlet filter. Once pressurized, the water exits the pump and enters the accumulator, which reduces the pressure ripples.
If called for by the project, the abrasive metering system adds abrasive material to the water. The water then flows into the cutting head, which is controlled by a water off valve. A robotic system component controls the flow of water through the valve. As necessary, it starts and stops flow to cut the material at the appropriate times.
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Why Partner With Metal Craft?
Established in 1964 and incorporated in 1969, Metal Craft Spinning and Stamping is now operated by fourth-generation family members. Our commitment to quality, on-time delivery, and personalized customer service has resulted in our customers coming back to us for their manufacturing needs time and again.
Whether you require metal spinning, stamping, hydroforming, or waterjet cutting services, we’ve got you covered. Equipped with decades of industry experience and state-of-the-art fabrication equipment, we have the knowledge and skills to deliver precise and accurate metal components that fully meet your needs.
For additional information about our waterjet cutting or other manufacturing capabilities, contact us or request a quote today. One of our experts will answer and address any questions or concerns you may have about the process or your project.
About Us
Metal Craft Spinning and Stamping was incorporated in 1969 and specializes in the manufacturing of metal components of all shapes and sizes. Our department is highly skilled in the ancient trade of hand metal spinning as well as automatic metal spinning utilized with state-of-the-art CNC machines. A number of hydraulic presses and hydroforming machines have been acquired, complimenting our metal spinning capabilities.
Metal Craft Spinning and Stamping commits itself to exceed the expectations of our customers with quality products and on-time delivery through continuous improvements and customer collaboration.
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