MFET 4210. 1. Basic Principles 2. Hardware 3. Abrasives 4. Parameters 5. Capabilities 6....
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Transcript of MFET 4210. 1. Basic Principles 2. Hardware 3. Abrasives 4. Parameters 5. Capabilities 6....
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ABRASIVE WATER JET MACHINING
MFET 4210
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Topics for Today
1. Basic Principles 2. Hardware 3. Abrasives 4. Parameters 5. Capabilities 6. Advantages 7. Disadvantages
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1. Basic Principles
How does it work? High pressure water with abrasive eroding
material Small diameter orifice or “jewel” to focus
energy Erosion of material Jet of abrasive and water
20,000 – 90,000 psi Up to 600 mph
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2. Hardware
Intensifier Pump Nozzle Abrasive Delivery System Catcher CNC Control
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Hardware
Intensifier Pump Components Hydraulic Pump Pistons Cylinders Check valves Attenuator
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Hardware Delivery System
Nozzle Jewel Abrasive inlet Guard Mixing Tube
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Hardware Delivery System
Nozzle Jewel
Diameter ranges from .005 - .020”
Usually sapphire, sometimes ruby or diamond
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Hardware Delivery System
Nozzle Abrasive Inlet
Feeds from abrasive feed system
Venturi pulls in abrasive
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Hardware Delivery System
Nozzle Mixing Tube
Abrasive and water mix evenly
Must be exactly in line Composite carbide
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Hardware
Abrasive Delivery System Provide fixed delivery rate Gravity or air fed
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Hardware
Catcher Slows jet of water down Reduces noise and dust Catches dust
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Hardware CNC Controllers
Traditional control PCs
Cheaper Easier to update to newer and faster software
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3. Abrasives
Usage ½ to 2 pounds per minute $0.15 to $0.40 per pound
Types Garnet Olivine
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Abrasives
Garnet Most common at 80 mesh Naturally occurring mineral Less dusting Typical to reuse 2 or 3 times
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Abrasives
Olivine Cheaper than garnet Softer than garnet
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4. Parameters
Pressure Nozzle or jewel diameter Feed or traverse rate Nozzle standoff distance
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Parameters
Pressure Ranges from 20-90,000 psi
Less than 60,000 psi most common Higher pressure for harder materials and
thicker cuts Harder on equipment
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Parameters
Nozzle Diameter Large range depending on application Jet usually .020-.050”
Horsepower = 0.58*P*Q P = pressure in ksi Q = flow rate in gpm
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Parameters
Feed Rate Varies greatly depending on
Type of material Thickness Hardness Quality of cut needed
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Parameters
Standoff Usually .010 to 0.200”, up to 1” Higher distance causes frosting
Eliminated by cutting underwater
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5. Capabilities
Tolerances Materials Geometries Examples of use
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Capabilities
Tolerances +-.004 to +-.008” Vast majority of industry cuts at +-.010” or
more
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Capabilities Materials
Cuts basically anything Diamond, some ceramics
6.5” Ti
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Capabilities
Geometry Stacking parts 5-axis milling
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Capabilities
Geometry Very thin to
very thick cuts Flat sheets of
material
10.25” Tool Steel
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6. Avantages
No HAZ Temp may rise to 120 degrees F Catch tank and water absorb heat
Very small kerf .020-.050”
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Avantages
Minimal cutting forces 5 pounds max down force Very low side forces Clamping forces are very low
Brittle or fragile work pieces
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Avantages
Fast and accurate
Minimal fixturing
Omni-directional
Cuts any type of materials Nonhomogeneous
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Avantages
No tools to sharpen, only “tool” is the nozzle
Environmentally friendly Garnet can be dumped in landfill Water can be filtered and reused
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7. Disadvantages
Lag Only a factor if finish is important Very similar to cutting torch lag lines
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Disadvantages Taper
Parts cut with taper Can be compensated for by software Increases with nozzle wear
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Disadvantages
Less accurate than traditional machining Very hard materials not very practical
application Traverse rate is so slow, costs add up
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Disadvantages
Can delaminate some materials Fiberglass, some composites Preventable with pilot hole from drill
Cost Setup ranges from $20,000-$300,000
Average machine runs $150,000 Thickness of cut
Price increases dramatically for >2” metal cuts
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Disadvantages
Nozzle wear Consumable nozzle wears Causes stray cutting Increases kerf Decreases finish quality
Very loud Reduced if cut underwater
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Applications
Machine shops Artists
Stone, glass, marble Aerospace
Titanium, Inconel, composites Rapid prototyping Universities Automotive industry Custom flooring work
Tiles
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Summary
Very versatile, powerful technology Growing use and applications Constantly getting better and more
capable
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Sources
Nontraditional Machining Processes, E. J. Weller
http://www.jetedge.com http://waterjets.org/ http://www.h2ocut.com/ http://www.universalminerals.com/ http://www.flowcorp.com/