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Transcript of KMT US Inc. - KMT Waterjet Waterjet Basics. KMT US Inc. - KMT Waterjet The KMT Waterjet Network...
KMT US Inc. - KMT Waterjet
Waterjet Basics
KMT US Inc. - KMT Waterjet
The KMT Waterjet Network
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Main Office GermanyMain Office USA
KMT US Inc. - KMT Waterjet
What is Waterjet Cutting?
Erosion process of material
KMT US Inc. - KMT Waterjet
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
What is an Orifice?
The primary component of the nozzle where the energy formation
occurs
KMT US Inc. - KMT Waterjet
Waterjet (WJ)?
Orifice
Waterjet
Nozzle
KMT US Inc. - KMT Waterjet
• Plastic
• Foam
• Paper
• Rubber
• Food
• Gaskets
Waterjet Applications
KMT US Inc. - KMT Waterjet
Waterjet Applications
KMT US Inc. - KMT Waterjet
Abrasive Waterjet (AWJ)?
Abrasive
Jet
High Pressure Water
KMT US Inc. - KMT Waterjet
How AWJ Works?
KMT US Inc. - KMT Waterjet
Abrasive Waterjet Application
KMT US Inc. - KMT Waterjet
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
Direct Drive Pump / Mechanical Pump
KMT US Inc. - KMT Waterjet
Intensifier Pump
KMT US Inc. - KMT Waterjet
Intensifier Topwork?
KMT US Inc. - KMT Waterjet
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
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
KMT Intensifier Components
KMT US Inc. - KMT Waterjet
KMT Intensifier Components
KMT US Inc. - KMT Waterjet
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
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
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
Pure Waterjet Turnkey System
Optional WaterTreatment SystemHP INTENSIFIER
NOZZLEASSEMBLY
ORIFICE
WATERJET
NOZZLE
KMT US Inc. - KMT Waterjet
Waterjet
HP WATER
HYDRAULIC OIL
LP WATER
TOPWORK CONSUMABLESON/OFF VALVE
Electric Motor & Hydraulic Power Pack
KMT US Inc. - KMT Waterjet
Abrasive Waterjet
ABRASIVE FEEDER
NOZZLE
ON/OFF VALVETOPWORK CONSUMABLES
Electric Motor & Hydraulic Power Pack
HP WATER
HYD. OIL
LP WATER
KMT US Inc. - KMT Waterjet
Abrasive
KMT US Inc. - KMT Waterjet
Abrasive Consumption
Nozzle SizeOptimal
Abrasive RateMaximum
Abrasive Rate
Practical Abrasive Mesh
Size
7/21 0.3 lb/min 0.4 lb/min120, 150, 180,
200
10/30
9/300.75 lb/min 1.0 lb/min 80, 100, 120
14/43
13/431.3 lb/min 1.5 lb/min 50, 65, 80
KMT US Inc. - KMT Waterjet
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
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
Dynamic Waterjet vs. Standard Waterjet
Very Expensive
High Maintenance
Software issues
KMT US Inc. - KMT Waterjet
Sizing
KMT US Inc. - KMT Waterjet
Orifice Size Vs Horsepower, 60,000 PSI
Orifice Size 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 2 3 4 5 7 10 14
0.009 1 2 2 3 4 6 8
0.010 1 1 2 2 3 5 7
0.011 1 1 2 2 4 5
0.012 1 1 1 2 3 4
0.013 1 1 1 2 3 4
0.014 1 1 1 2 3
0.015 1 1 2 3
0.016 1 1 2 2
0.017 1 1 2
0.018 1 1 2
0.019 1 1 1
0.020 1 1
0.021 1 1
0.022 1 1
KMT US Inc. - KMT Waterjet
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 2 3 4
0.014” - 1 - 2
KMT US Inc. - KMT Waterjet
Waterjet Advantages
KMT US Inc. - KMT Waterjet
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
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
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
Titanium Alloy..
KMT US Inc. - KMT Waterjet
Brass.. SS.. Aluminum..
KMT US Inc. - KMT Waterjet
Why Waterjet?
Versatile and Flexible Process
Marble, granite, ceramic tiles & glass
Fiberglass, composites & laminates
Etc….
KMT US Inc. - KMT Waterjet
Stone.. Glass..
KMT US Inc. - KMT Waterjet
Waterjet Parameters
KMT US Inc. - KMT Waterjet
Key Parameters?
Operating pressure
Abrasive: flow rate, type & mesh size
Standoff distance
Cut rate; AWJ a single parameter process
KMT US Inc. - KMT Waterjet
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
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
KMT US Inc. - KMT Waterjet
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
Edge Quality
KMT US Inc. - KMT Waterjet
Edge Quality
KMT US Inc. - KMT Waterjet
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
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
Motion Equipment
KMT US Inc. - KMT Waterjet
XY Tables: Mechanics
Belt Drives +/- 0.010”
Rack & Pinion +/- 0.005”
Ball Screw (Ground/Rolled) +/- 0.003”
Linear Drives (High Speed New Technology)
KMT US Inc. - KMT Waterjet
Controllers
Dedicated
– Allen Bradley, Fanuc, Mitsubishi, Num….– Expensive, reliable, repeatable, closed architecture 40 – 50k
PC Based: Open architecture & inexpensive 10-20k
– Open architecture & inexpensive 10 - 20k– Dedicated to Manufacturer
KMT US Inc. - KMT Waterjet
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
XY Motion Configuration
KMT US Inc. - KMT Waterjet
XYZ Motion Configuration
KMT US Inc. - KMT Waterjet
Waterjet Practicalities
KMT US Inc. - KMT Waterjet
Feasibility Questions
Material WJ or AWJ
Existing Method & Process
Justification & Why WJ
Primary/Secondary Operation
Cycle Time Concern
Programming Method
Parts Small vs. Large
Material Stacking
Sheet Metals
Loading/Unloading
Production, Dedicated or Job Shop
# of Shifts
KMT US Inc. - KMT Waterjet
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
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
Non-Compelling Application
Extrusions
Layered non-homogeneous material
Tempered Glass
Tubes
KMT US Inc. - KMT Waterjet
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
Supply Water Quality
KMT US Inc. - KMT Waterjet
Water Quality Standards
CATEGORYMINIMU
M BETTER BEST
ALKALINITY (MG/L) 50 25 10
CALCIUM (MG/L) 25 5 0.5
IRON (AS Fe) (MG/L) 0.2 0.1 0.01
MAGNESIUM (AS Mg) (MG/L) 0.5 0.1 0.1
MANGANESE (AS Mn) (MG/L) 0.1 0.1 0.1
pH (SU) 6.5-8.5 6.5-8.5 6.5-8.5
SILICA (MG/L) 15 10 1
TDS (MG/L) *** 200 100 5
HARDNESS (AS CaCO3) (MG/L) 25 15 1
KMT US Inc. - KMT Waterjet
End