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Home / Laser, Waterjet, Plasma Cutting Systems

Laser, Waterjet, Plasma Cutting Systems

A yearend review of some of the current advances and application capabilities in each of these metal cutting technologies.

Posted: November 5, 2014

An Eagle fiber laser cutting head with laser beam from MSS Lasers is one of the most advanced systems in the market, with linear drives on all three axes and a low inertia carbon fiber transverse bridge construction that can accelerate up to 6G with achieve cutting speeds in excess of 100 m/min.
Accuracy inside the Eagle fiber laser from MSS Lasers is assured through the rigidity of the carbon fiber bridge and the dynamic polymer concrete frame that minimizes vibration and heat related deflection of the machine geometry. With bed sizes up to 6 m x 2.5 m, this system increases material utilization by efficiently nesting jobs and cutting very large parts.
The SUPER TURBO-X laser-cutting system with Preview 3 control from Mazak Optonics uses proprietary vibration dampening frame and integrated laser resonator that ensure stable, high accuracy cutting of plates. The constant beam length construction provides uniform cutting performance across the machine table. 
The TruLaser 8000 2D laser cutting machine from TRUMPF can process material up to 52 ft long and up to one inch thick using a 6 kW laser, making it ideal for processing very large parts or for job shops looking to expand their capacities and range of services.
KBM separate rotor and stator packages on ProLaser CL laser cutting systems from Proteck are supplied in kit form and directly mounted on the machine within their own bearing system and protective cover, with power and encoder connectors built-in. The mounting arrangement directly couples the large diameter pinion shaft to the rotor as a single solid assembly, restricting lost motion and potential unwanted harmonics that a flexible coupling may allow.
On ProLaser CL laser cutting systems from Proteck, S700 servo drives with multi-feedback capability from Kollmorgen are used with both resolver feedback, mounted on the KBM motor for commutation, and magnetic linear scales for the position loop. The feedback protocol is SSI absolute, EnDAT or alternatively BiSS, to suit a choice of CNC controllers with set-up and monitoring via EtherCAT that is integrated in all S700 drives.
With a maximum sheet size of 3.1 m x 1.6 m, next-generation ProLaser CL flat sheet cutting machines from Proteck also use AKM series rotary servo motors with Micron™ series planetary gearheads that are brake fitted for the Y-axis as well as the Z-axis.
The highly rigid MicroMAX JetMachining® Center from OMAX has a table size of 2 ft 4 in x 2 ft 4 in and an X-Y cutting travel of 2 ft x 2 ft. Its new Mini Tilt-A-Jet® cutting head nearly quadruples the position accuracy of the nozzle for even more precise cutting with virtually zero taper in most materials up to 3 in thick. The head is also 25 percent smaller and lighter and nearly twice as rigid for less deflection.
Intelli-MAX 21 for JetMachining Centers from OMAX not only optimizes tool paths automatically, it provides precise predictability of cutting speeds, taper, jet lag and other abrasivejet factors of those particular tool paths to achieve the highest levels of waterjet cutting speed and performance.
Supplied with a MAXJET 5i nozzle, the high precision A-Jet cutting head from OMAX cuts accurate beveled edges at angles determined by either the machine operator or part program. The A-Jet adds two motion axes, enabling the nozzle to tilt over a range of 0 deg to 60 deg from the vertical position. It can be used to easily produce beveled edges or cut countersunk holes, as well as machine parts with complex geometries. With its additional axes of motion, the A-Jet allows production of beveled edges in preparation for welding operations. The use of this accessory eliminates the need for many secondary machining and grinding operations.
With a Rotary Axis, JetMachining Centers from OMAX have up to 6-axis cutting capabilities that can create accurate complex 3D parts from pre-existing CAD drawings or DXF files. With the expanded parametric shape library, the Rotary Axis is ideal for pipe and tube cutting, simplifying challenging projects such as intersecting pipe fittings.
FlowXpert 2015 is a robust CAD/CAM software platform from Flow International that introduces significant new waterjet capabilities for 3D pathing and cutting that allow shops to work more effectively and with less complexity in 3D.
The DynaBeam laser height sensing technology from Flow maps the natural state of materials, reducing the need for manual adjustment throughout cutting. Operators can choose between setting the standoff height between the waterjet nozzle and the workpiece before every pierce, or pre-mapping an entire workpiece quickly and easily.
The price of a build-it-yourself WARDKit from WARDJet includes everything necessary to start waterjet cutting, including the tank, cutting head, grates, intensifier pump, control software, human machine interface and access to technical support. Upgrades and options on pump horsepower, controller style, and abrasive delivery system allow perfect configuration.
The Emerald 0606, the smallest waterjet ever manufactured by WARDJet, is designed to offer all the quality of a large, expensive waterjet cutting system at a reduced size and cost. Because of its rigid, sturdy tank design, the Emerald 0606 is capable of handling 12 in thick stainless steel just as easily as a 2 in sheet of foam.
The J-Series is a low-cost water-only waterjet from WARDJet that uses belt drive technology to cut at speeds of 2,500 ipm with an acceleration and deceleration rate of 0.2 m/s2. J-Series waterjets are ideal for cutting high volumes of parts where margins are low and tolerances are not as demanding.
The L-Series, the fastest cutting waterjet from WARDJet, uses a linear motion drive system with excellent accuracy, repeatability and reliability that cuts 7,000 ipm with an acceleration and deceleration rate of 1 sq m. The thick-walled steel tubing frame of the L-Series can accommodate multiple 5-axis cutting heads.
The FARM-JET waterjet cutting system from Jet Edge brings the power and versatility of ultra-high pressure waterjet cutting technology to farm machine shops for the price of a new fully loaded 1 ton 4X4 pickup truck, without requiring special electrical service.
The affordably priced direct-drive style Eco-Jet PTO ultra-high pressure waterjet pump is ideal for rural machine shops or areas with limited power because it utilizes a tractor PTO shaft to produce ultra-high pressure water for precision cutting, cleaning and surface preparation. It runs a .015 in waterjet orifice and can power most waterjet cutting systems and waterjet tools.
The economically priced BOSS-CUTTER water jet cutting system from Jet Edge is ideal for small shops. It has a 40 in x 40 in (1 m x 1m) work envelope with one abrasivejet cutting head and a motorized Z-axis with 5 in (513 mm) of travel that is controlled with a Windows PC (sold separately) and uses a FlashCut Pro-Series Stepper Controller and FlashCut CNC software. It also includes IGEMS path generation software and a hand-held controller pendant for operator convenience.
The compact SGX automated plasma and oxy-fuel cutting machine from ESAB features the easy-to-use Vision® T5 touch-screen CNC with built-in automatic nesting, as well as automatic gas controls and plasma automation powered by m3 Plasma technology. Performance and accuracy are assured with a heavy steel beam, precision machined mating surfaces, and linear rail. This rugged design ensures smooth motion, accuracy and long term machine durability. SGX enables higher productivity with rapid cut-to-cut cycle times through the integration of dual-side, high-speed AC drives and a fast torch lifter.
The do-it-yourself V Series Plasma from MultiCam features a custom-engineered, extruded aluminum frame with steel leg supports for high strength and rigidity. Automatic torch height is standard along with powerful, dual X-axis drive motors and Hypertherm PowerMax plasma torches. The easy-to-use, handheld operator interface features graphic icons for all machine functions.
The V-PRO CNC Plasma system from MultiCam has a standard, heavy-duty, all-steel water table with integrated bladder capable of production processing of sheet steel up to 1.25 in thick without the need for fume evacuation. The CNC plasma system uses a Hypertherm MAXPRO200 (200 amp) power supply engineered for heavy-duty, high capacity mechanized cutting.
The compact, durable 5-axis bevel plasma head from MultiCam uses aluminum castings for weight reduction and rigidity, has improved crash protection and ease of maintenance, and introduces the “phi” and “theta” axes of movement for cutting complex parts with bevels up to 45 deg in 2 in thick mild steel.
Designed to remove up to 25 lb of metal per hour, the PAK 200i manual gouging and plasma cutting system from Victor Thermal Dynamics can also hand cut 2 in thick mild steel at 10 ipm.
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Flow International is a global technology-based manufacturer committed to world-class waterjet cutting and surface preparation solutions that offer dynamic business growth opportunities and increased profitability to customers.

Flow International Corporation, 23500 64th Avenue South, Kent, WA 98032, 253-850-3500, [email protected], www.flowwaterjet.com.

ASSEMBLE YOUR OWN WATERJET
Never before has a manufacturer offered a top-of-the-line system that they currently sell in kit form. WARDJet, Inc. (Tallmadge, OH) now announces the WARDKit Series of waterjets, where owners get the same quality, engineering and design of a virtually identical Emerald Series waterjet – from tank design and manufacturing down to the cutting head – in an easy-to-assemble kit for 40 percent off!

http://youtu.be/Q0_Xh2qcM1E

With this package, even the control software included is identical to all of company’s high-end systems. This same software is used to run the large format combination 5-axis waterjet and mill currently installed at an aerospace research facility in the United Kingdom. The WARDKit is manufactured entirely in America and available in 5 ft x 5 ft, 5 ft x 10 ft, and 2 ft x 2 ft sizes.

Customers start by attending the commitment-free training course, then return home with the confidence and knowledge they need to assemble a waterjet themselves. The price of a WARDKit includes everything necessary to start waterjet cutting, such as the tank, cutting head, grates, intensifier pump, and human machine interface. The package even includes access to the company’s renowned technical support. Upgrades and options on pump horsepower, controller style, and abrasive delivery system are also available to allow for perfect configuration.

Prices for the WARDKit begin as low as $65,000. Financing is available for those who qualify for as little as $67 per business day! Adding a waterjet to the shop has never been easier, more affordable, or fun!

The company also offers the Emerald 0606 (2 ft x 2 ft) and the Emerald 0612 (2 ft x 4 ft) to the existing Emerald Series Line of low cost, American made waterjets. The Emerald 0606 offers a cutting envelope of 2 ft by 2 ft and 12 in of Z-travel and is uniquely designed with ballscrew drives and a cantilever-style arm. This short-travel, cantilever architecture effectively balances the reduced machine footprint and number of moving parts of the Emerald 0606, while maximizing cutting envelope and maintaining overall stiffness.

The Emerald 0612 offers double the cutting envelope at 2 ft by 4 ft. The cantilever-style arm is ballscrew driven, the tank is beefed up for extra support, and the overall footprint is small. The Emerald 0612 offers the advantage of indexing sheets of unlimited length from front to back – standard 4 ft by 8 ft sheets of material up to 2 in thick can be cut with greater convenience.

The company has also designed two high-speed, high-production, American-made waterjets: the J-Series and L-Series. These reliable waterjet cutting systems are paired with innovative solutions for material handling and automation to provide a competitive edge in the waterjet industry.

http://youtu.be/K55wtLZqoNg

The J-Series can accommodate the addition of material handling solutions such as loading/off-loading tables, as well as optical sensors to control chain feed tables or pinch feed rollers. The modular design of the J-Series waterjet makes it possible for small design changes to turn a standard waterjet system into a machine designed specifically for your application.

The L-Series is the fastest cutting waterjet offered by WARDJet. It uses a linear motion drive system, renowned for its excellent accuracies, placement repeatability, and reliability allowing customers to cut at incredible speeds of 7,000 ipm with an acceleration and deceleration rate of 1 m/ s2. The frame of the L-Series is made of thick-walled steel tubing that can accommodate multiple 5-axis cutting heads.

http://youtu.be/gaZPPw20l6Q

WARDJet, Inc. 180 South Avenue, PO Box 517, Tallmadge, OH 44278, 330-677-9100, [email protected], www.wardkit.com.

WATERJET CUTTING FOR FARM MACHINE SHOPS
Waterjet cutting has numerous advantages over other cutting methods. Waterjet cuts virtually any material and thickness without creating a heat-affected zone (HAZ), case hardening or recast, or molecular change of the material. Unlike plasma, waterjet cuts without creating any noxious fumes.

Jet Edge, Inc. (St. Michael, MN) now offers the FARM-JET® waterjet cutting system, a 55,000 psi waterjet cutting system designed and priced especially for the farm machine shop. An industry first, FARM-JET brings the power and versatility of ultra-high pressure waterjet cutting technology to farm machine shops for the price of a new fully loaded 1 ton 4X4 pickup truck, without requiring special electrical service.

http://youtu.be/UOGJeI_WYWA

The FARM-JET system includes a 40 in x 40 in (1 m x 1 m) waterjet cutting table and an Eco-Jet PTO direct drive waterjet pump (see below) that utilizes a tractor’s PTO shaft to produce 1 gpm of 55,000 psi water. The system includes one abrasivejet cutting head and a motorized Z-axis with 5 in (130 mm) of travel. The FARM-JET system is controlled with a Windows® PC (sold separately) and uses a FlashCut Pro-Series Stepper Controller and FlashCut CNC software. It also includes IGEMS path generation software and a hand-held controller pendant for operator convenience.

The Eco-Jet PTO ultra-high pressure waterjet pump, an affordably priced direct-drive style waterjet pump designed especially for use in rural machine shops or in areas with limited power, is an industry-first that utilizes a tractor PTO shaft to produce ultra-high pressure (UHP) water for precision cutting, cleaning and surface preparation applications. It runs a .015 in waterjet orifice and can power most manufacturers’ waterjet cutting systems and waterjet tools. Unlike traditional industrial waterjet pumps, the Eco-Jet PTO requires only a standard 120 V 60 Hz power source, making it practical for farm machine shops and shops with a limited power supply. The Eco-Jet PTO pump is made in the U.S.

With the Eco-Jet PTO is available for 540 RPM and 1000 RPM PTO shafts and Category 1 and 2 three point hitches (tractor sold separately). In addition to a 120 V 60 Hz power source, it also requires a fresh water source. The FARM-JET system requires a 115V 60 Hz or 230V 50 Hz power source, fresh water source and a suitable tractor.

“This is the first waterjet cutting system that is designed and priced for the farm shop,” noted Jude Lague, the president of Jet Edge. “Until now, if you wanted a waterjet, it meant a six-figure investment and access to 460 volt power. Now you can own a waterjet for the price of a new truck and run it off standard household electric and your tractor PTO. With a waterjet system, you can create a nice source of additional revenue and, if you need a part fast, you can cut it in minutes instead of waiting for days or weeks to have it fabricated and shipped. You also can have some fun with it cutting custom tile inlays for your house or racecar parts for your dirt track team.”

The company also offers the BOSS-CUTTER water jet cutting system, an economically priced water jet designed especially for small shops that features a 40 in x 40 in (1 m x 1m) work envelope. This system includes one abrasivejet cutting head and a motorized Z-axis with 5 in (513 mm) of travel that is controlled with a Windows PC (sold separately) and uses a FlashCut Pro-Series Stepper Controller and FlashCut CNC software. It also includes IGEMS path generation software and a hand-held controller pendant for operator convenience.

BOSS-CUTTER is powered by a Jet Edge waterjet pump. The company offers the widest range of waterjet pumps in the industry, including 30 hp to 280 hp hydraulic intensifier pumps in 36 ksi, 60 ksi and 90 ksi models, electric and diesel, and direct drive pumps. In fact, Jet Edge and Alliance Automation, LLC (Grand Blanc, MI) announced that Alliance Automation, a leading designer and manufacturer of custom industrial automation and robotic systems, is powering its latest generation of robotic waterjet trimming cells with Jet Edge intensifier pumps.

Featuring dual wall-mounted Motoman HP20D robots and Jet Edge 60 ksi (4100 bar) iP60-50 waterjet intensifier pumps, Alliance Automation’s new 6-axis robotic waterjet trimming cell leads the industry in precision and dependability, with Motoman’s ±0.06 mm repeatability and Jet Edge’s reliable tie-rod intensifier design. The cell’s sturdy, compact frame design allows stability to both the tool and robots to ensure consistent tight part tolerances.

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