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Waterjet Basics KMT US Inc. - KMT Waterjet.

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Presentation on theme: "Waterjet Basics KMT US Inc. - KMT Waterjet."— Presentation transcript:

1 Waterjet Basics KMT US Inc. - KMT Waterjet

2 The KMT Waterjet Network
Main Office USA Main Office Germany Canada Montreal Korea Seoul Washington Olympia Sweden Ronneby China Shanghai England Birmingham Poland Warszawa Illinois Chicago France Paris Missouri Springfield New Jersey Shamong Italy Milan Oklahoma Tulsa Spain Madrid California Fresno Georgia Atlanta U.A.E. Dubai India Mumbai Mexico Mexico City Brazil Sao Paulo KMT US Inc. - KMT Waterjet

3 What is Waterjet Cutting?
Erosion process of material KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

5 What is an Orifice? The primary component of the nozzle where the energy formation occurs KMT US Inc. - KMT Waterjet

6 Waterjet (WJ)? Nozzle Orifice Waterjet KMT US Inc. - KMT Waterjet

7 Waterjet Applications
Food Plastic Foam Paper Gaskets Rubber KMT US Inc. - KMT Waterjet

8 Waterjet Applications
KMT US Inc. - KMT Waterjet

9 Abrasive Waterjet (AWJ)?
High Pressure Water Abrasive Jet KMT US Inc. - KMT Waterjet

10 How AWJ Works? KMT US Inc. - KMT Waterjet

11 Abrasive Waterjet Application
KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

13 Direct Drive Pump / Mechanical Pump
KMT US Inc. - KMT Waterjet

14 Intensifier Pump KMT US Inc. - KMT Waterjet

15 Intensifier Topwork? KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

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 Seal Removal The KMT Pump has the lowest noise level The KMT Pumps can be automatically balancing KMT US Inc. - KMT Waterjet

18 KMT Intensifier Components
KMT US Inc. - KMT Waterjet

19 KMT Intensifier Components
KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

23 Pure Waterjet Turnkey System
Optional Water Treatment System HP INTENSIFIER NOZZLE NOZZLE ASSEMBLY ORIFICE WATERJET KMT US Inc. - KMT Waterjet

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

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

26 Abrasive KMT US Inc. - KMT Waterjet

27 Practical Abrasive Mesh Size
Abrasive Consumption Nozzle Size Optimal Abrasive Rate Maximum Abrasive Rate Practical Abrasive Mesh Size 7/21 0.3 lb/min 0.4 lb/min 120, 150, 180, 200 10/30 9/30 0.75 lb/min 1.0 lb/min 80, 100, 120 14/43 13/43 1.3 lb/min 1.5 lb/min 50, 65, 80 KMT US Inc. - KMT Waterjet

28 Abrasive What is abrasive? What is mesh size?
What type of abrasive is common? What is the pricing of abrasive? Is abrasive recyclable? KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

30 Dynamic Waterjet vs. Standard Waterjet
Very Expensive High Maintenance Software issues KMT US Inc. - KMT Waterjet

31 Sizing KMT US Inc. - KMT Waterjet

32 Orifice Size Vs Horsepower, 60,000 PSI
15 HP 30 HP 50 HP 60 HP 75 HP 100 HP 150 HP 200 HP 0.005 2 4 7 8 10 14 21 28 0.007 1 3 5 0.009 6 0.010 0.011 0.012 0.013 0.014 0.015 0.016 0.017 0.018 0.019 0.020 0.021 0.022 KMT US Inc. - KMT Waterjet

33 Horsepower & Pump Capacity?
55 ksi Operating Pressure Orifice 30 HP 50 HP 75 HP 100 HP 0.007” 2 4 6 8 0.010” 1 3 0.014” - KMT US Inc. - KMT Waterjet

34 Waterjet Advantages KMT US Inc. - KMT Waterjet

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

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 KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

38 Titanium Alloy.. KMT US Inc. - KMT Waterjet

39 Brass.. SS.. Aluminum.. KMT US Inc. - KMT Waterjet

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

41 Stone.. Glass.. KMT US Inc. - KMT Waterjet

42 Waterjet Parameters KMT US Inc. - KMT Waterjet

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

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 KMT US Inc. - KMT Waterjet

45 Facts: Waterjet Tolerances?
Taper control works best with thick metals AWJ practical tolerances, +/ ” plus Tight tolerances are expensive to hold Critical: Motion equipment, work envelope KMT US Inc. - KMT Waterjet

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 KMT US Inc. - KMT Waterjet

47 Edge Quality KMT US Inc. - KMT Waterjet

48 Edge Quality KMT US Inc. - KMT Waterjet

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

50 Waterjet vs. Others AWJ EDM Laser Plasma Gas Thickness + + + -
Cut Rate - - Surface Finish Heat Affected Zone Environment Safety Material Flexibility Secondary Operation Operation Cost Capital Investment 100% 60% 200% 80% 40% KMT US Inc. - KMT Waterjet

51 Motion Equipment KMT US Inc. - KMT Waterjet

52 XY Tables: Mechanics Belt Drives +/- 0.010” Rack & Pinion +/- 0.005”
Ball Screw (Ground/Rolled) +/ ” Linear Drives (High Speed New Technology) KMT US Inc. - KMT Waterjet

53 Controllers Dedicated Allen Bradley, Fanuc, Mitsubishi, Num….
Expensive, reliable, repeatable, closed architecture 40 – 50k PC Based: Open architecture & inexpensive 10-20k Open architecture & inexpensive k Dedicated to Manufacturer KMT US Inc. - KMT Waterjet

54 Motion Precision Positional Accuracy Per foot or per axis
Linear per single axis Dynamic per dual axis Repeatability Tolerance (applied only to finished part) KMT US Inc. - KMT Waterjet

55 XY Motion Configuration
KMT US Inc. - KMT Waterjet

56 XYZ Motion Configuration
KMT US Inc. - KMT Waterjet

57 Waterjet Practicalities
KMT US Inc. - KMT Waterjet

58 Feasibility Questions
Parts Small vs. Large Material Stacking Sheet Metals Loading/Unloading Production, Dedicated or Job Shop # of Shifts Material WJ or AWJ Existing Method & Process Justification & Why WJ Primary/Secondary Operation Cycle Time Concern Programming Method KMT US Inc. - KMT Waterjet

59 Feasibility Questions
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 KMT US Inc. - KMT Waterjet

60 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 KMT US Inc. - KMT Waterjet

61 Non-Compelling Application
Extrusions Layered non-homogeneous material Tempered Glass Tubes KMT US Inc. - KMT Waterjet

62 Terminology Burr Delamination Frosting Taper Fraying Frost Piercing
Kerf Striations Rooster Tail/ Stream Lag Splash Back Corners & Curves Practical Thickness & Limitations KMT US Inc. - KMT Waterjet

63 Supply Water Quality KMT US Inc. - KMT Waterjet

64 Water Quality Standards
CATEGORY MINIMUM BETTER BEST ALKALINITY (MG/L) 50 25 10 CALCIUM (MG/L) 5 0.5 IRON (AS Fe) (MG/L) 0.2 0.1 0.01 MAGNESIUM (AS Mg) (MG/L) MANGANESE (AS Mn) (MG/L) pH (SU) SILICA (MG/L) 15 1 TDS (MG/L) *** 200 100 HARDNESS (AS CaCO3) (MG/L) KMT US Inc. - KMT Waterjet

65 End KMT US Inc. - KMT Waterjet


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