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High Water Marks

A review of some of the latest advances in waterjet cutting technology and related accessories that are now on the market.

Posted: April 28, 2015

The PAC 60 Five-Axis Cutting Head from TECHNI Waterjet offers bevel cutting capabilities for up to ±60 deg continuous rotation with taper elimination. Regardless of the geometry of the part to be cut, the PAC 60 will produce it without having to reposition the cutting head, saving time and producing higher quality parts. (first view)

The large i713-G2 Dual Station waterjet cutting machine with Tech-Sense Abrasive Monitoring from TECHNI Waterjet is ideal for unmanned high production operations. It cuts with dual heads operating under different programs over an area of 14 ft x 26 ft.

The efficient and economical 60,000 psi, 30 hp iP60-30 Waterjet Pump from Jet Edge draws half the amperage of a 50 hp pump, making it ideal for rural shops, R&D labs, schools and small budget-conscious waterjet cutting shops that desire the reliability of a hydraulic intensifier pump but have limited power.

The EDGE X-5 5-axis waterjet system from Jet Edge cuts complex taper-free and 3D parts from virtually any material and is available in a wide range of table sizes, from 5 ft x 5 ft to 24 ft x 13 ft.

The modular Streamline SL-VI Series Intensifier Pump from KMT Waterjet can be configured to deliver the power, productivity, and performance required to meet specific applications ranging from 15 hp to 200 hp, and from 60,000 psi to 90,000 psi.

The MAXIEM 2080 JetMachining Center is one of three new waterjet cutting systems from OMAX that are ideal for the wide range of modern large format machining found in job shops, OEMs, metal service centers and other fabricators competing in large-scale production.

Intelli-CAM 3 software, which interfaces directly with the intuitive Intelli-MAX Software Suite from OMAX, easily generates 3D tool paths from solid 3D models as well as quickly performs 3D to 2D file conversions.

The Hydrocut LX from ESAB merges waterjet technology with plasma cutting on one machine in a patented combination of thermal and non-thermal processes that operate on the same gantry, allowing the machine to cut with the high accuracy of waterjet where needed, but employ the high speed and low cost of plasma whenever possible. This enhances productivity and reduces part costs. (first view)

The Hydrocut LX from ESAB delivers the high precision of waterjet cutting to the heavy fabrication and steel service industries. The advantages of a non-thermal process and the precision of abrasive waterjet let operators produce perfect finished parts that require no secondary cleanup or machining.

This combination cut part is a typical example of why users opt for the waterjet-plasma combination. The part is 1.5 in thick steel that required a highly accurate, round hole for a shaft. The outside of the part did not require the same level of precision, and so it was cut with the much faster plasma process. The internal hole was cut using 60,000 psi waterjet at 2 ipm. The outside of the part was cut with 360 amp oxygen plasma at 48 ipm. Cutting the entire part with waterjet would have taken about 26 minutes. By using waterjet only where needed, and using plasma on the rest of the contours, this part took less than six minutes to cut, with the vast majority of that time being used to cut the hole.

The high-end Phantom Series waterjet cutting machine from Semyx reaches speeds as high as 5 mps (196 ips) and an astonishing 206 s of maximum acceleration.

The unique combination of waterjet cutting versatility and laser precision measuring capabilities make the DynaBeam Laser Sensing System from Flow the only non-contact material height sensing solution available in the industry. Operators 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.

Neolith material being cut with Dynamic XD on a Flow Mach 3 waterjet.

A sample of Neolith material that was cut by a Flow waterjet.

The ByJet Smart from Bystronic adds manufacturing capability to a shop by increasing their ability to process any material, as shown here, without compromise. (first view)

The ByJet Smart from Bystronic adds manufacturing capability to a shop by increasing their ability to process any material, as shown here, without compromise. (second view)

HIGH PRODUCTION WATERJET OPERATES UNMANNED
TECHNI Waterjet™, LLC (Lenexa, KS), a leading innovator in 2D and 3D waterjet cutting machinery for the fabrication, stone, glass and metal industries, has developed a new waterjet cutting machine to suit high production applications. This dual tank system was originally designed for a large fabrication company to increase their capabilities and is now available as a standard product from TECHNI. The new machine is an i713-G2 Dual Station with a cutting capacity of two (7 ft x 13 ft) tanks for a total cutting area of 14 ft x 26 ft, with the capabilities of bevel cutting with a PAC 60™ Five-Axis Cutting Head for up to ±60 deg continuous rotation with taper elimination. Regardless of the geometry of the part to be cut, the PAC 60 will produce it without having to reposition the cutting head, saving time and producing higher quality parts.

https://youtu.be/qaZpjPxmfzo

The i713 Dual allows for continuous production operation, as one tank is being loaded/unloaded while the other tank is cutting. The waterjet incorporates a number of features that allow one operator to control the entire system, including the Tech-Sense™ Abrasive Monitoring System, a remarkable technology that will dramatically increase profitability by reducing scrap, increasing uptime and reducing labor. An operator is no longer required to stand idle and watch a machine ‘just in case’ there is a problem. Tech-Sense will activate an audible alarm and a flashing light will warn the operator if the machine is not running efficiently, and will pause the machine if the problem could potentially damage the part or material being cut. Potential problems the system detects include:

Low abrasive being delivered to the cutting head. Possible cause: moist abrasive, blocked feed line due to foreign particles or kinked feed hose.
Plugged focusing tube. Possible causes: focusing tube too close to work piece, foreign material in tube.
Damaged orifice. Possible causes: general wear or erosion, foreign particle, poor water quality.
Water pressure drop. Possible causes: intensifier problem, high pressure hose leak, dump valve leak, cutting head leak.
Warn or damaged focusing tube
Inefficient cutting head set-up. Possible causes: too much or too little abrasive, cutting head loose, focusing tube not seated, orifice not assembled properly.

The i713-G2 Dual is equipped with Water Raise and Lower for Submerged Cutting, as well as the Quantum NXT™ 66 Dual pump that operates up to 60 percent more efficient than standard hydraulic intensifiers. The combination of cutting underwater and the Quantum NXT (the quietest pump in the waterjet industry, with less than 68 dBA) makes the i713-G2 Dual the cleanest and quietest waterjet setup available in the industry.

TECHNI Waterjet, LLC 15301 West 109th Street, Lenexa, KS 66219, 913-492-3700, Fax: 913-492-3702, [email protected], www.techniwaterjet.com.

WATERJET INTENSIFIER PUMP FOR SHOPS WITH LIMITED POWER
Waterjet systems manufacturer Jet Edge, Inc. (St. Michael, MN) introduces its new iP60-30 60,000 psi (4,100 bar), 30 hp (22 kW) hydraulic waterjet intensifier pump. Designed for waterjet shops that desire the reliability of a hydraulic intensifier pump but have limited power, the iP60-30 draws only 37 full load amps at 460 VAC (60 Hz) or 74 full load amps at 230 VAC (60 Hz). It is capable of producing 0.6 gpm (2.3 L/m) of ultra-high pressure water at a continuous operating pressure of 55,000 psi (3,800 bar). Economically priced and easy to maintain, the iP60-30 is ideally suited for rural shops, R&D labs, schools, and small budget-conscious waterjet cutting shops.

The iP60-30 intensifier pump features a reliable tie-rod design that eliminates threads on the high pressure cylinders, end caps, and hydraulic cylinders. This reduces the likelihood of cracking and increases component life. Matched metal components prevent galling of hydraulic components. The iP60-30 includes a hydraulic accumulator to provide smoother hydraulic pressure, reduce spikes and prolong hydraulic pump life.

The company also offers the EDGE X-5® 5-axis waterjet system with Aquavision® Di Control that cuts complex taper-free and 3D parts from virtually any material. Featuring innovative Permalign® EDGE technology, the EDGE X-5 dramatically increases waterjet cutting capabilities by producing chamfers, weld bevels and sophisticated 3D parts, such as impeller blades, all with a taper-free finish. The EDGE X-5 uses the Aquavision Di industrial PC controller that is designed specifically for 5-axis waterjet cutting. This powerful and flexible controller features an open architecture that gives operators the freedom to fine-tune programs from any CAD/CAM/nesting software, utilizing standard G&M code. The system’s Intelligent Work Envelope automatically adjusts the work envelope depending on the angle of the cut.

https://youtu.be/UZbHEFGdJMU

The EDGE X-5 is designed to provide years of dependable service in harsh industrial environments. Its rock-solid design separates the motion system from the catcher tank, eliminating vibration and ensuring maximum part quality. It is ball-screw driven for optimal precision and features direct-couple AC brushless digital servo motors and single or double carriages. Critical bearing components are protected by heavy metal covers with brush seals and positive air pressure. Other features include:

±0.001 in linear positional accuracy (over 12 in) per axis.
±0.001 in repeatability (bi-directional).
±0.003 in Renishaw ballbar tests of squareness and straightness (over 24 in) at 70 deg F.
Taper compensation and 50 deg beveling.
Rotary axis ±440 deg.
Focal point design.
Intelligent Work Envelope automatically adjusts to cut angle.
Motion components protected by metal covers, brush seals and filtered blowers creating a positive air pressure seal.
300 ipm contouring and 500 ipm rapid positioning (460V).
Accurate and predictable return to path.
Supports multiple cutting heads.

Jet Edge, Inc., 12070 43rd Street NE, St. Michael, MN 55376-8427, 763-497-8700, [email protected], www.jetedge.com.

MODULAR WATERJET PUMP CONFIGURES TO APPLICATION REQUIREMENTS
KMT Waterjet Inc. (Baxter Springs, KS) introduces the Streamline SL-VI Series pump as the right solution for every waterjet application. The Streamline SL-VI Series Intensifier is proven technology with millions of hours of operational usage in demanding waterjet environments. By choosing the SL-VI Series pump, the result is enhanced efficiency, productivity, and improved seal life with predictable maintenance schedules. These waterjet pumps are capable of delivering the necessary power, productivity, and performance based on shop requirements ranging from 15 hp to 200 hp, and from 60,000 psi to 90,000 psi. These new modular design water jet pumps are custom built based on a variety of options.

The all new color display dashboard control panel touch screen is easy to operate. There are 11 languages with universal icons for quick recognition. The SL-VI Touch Screen is software updateable, with optional gauges to choose from based on your needs. All standard systems offer Ethernet and USB Port with import/export capabilities. Software enhancements will include monitoring cycle counts, seal life and many more functions to optimize productivity and reduce downtime. Other key features and options include: