Waterjet Basics
KMT US Inc. - KMT Waterjet
The KMT Waterjet Network
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What is Waterjet Cutting?
Erosion process of material
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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
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What is an Orifice?
The primary component of the nozzle where the energy formation
occurs
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Waterjet (WJ)?
Nozzle
Orifice
Waterjet
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Waterjet Applications
• Food
• Plastic
• Foam
• Paper
• Gaskets
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• Rubber
Waterjet Applications
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Abrasive Waterjet (AWJ)?
High Pressure Water
Abrasive
Jet
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How AWJ Works?
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Abrasive Waterjet Application
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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
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Direct Drive Pump / Mechanical Pump
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Intensifier Pump
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Intensifier Topwork?
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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
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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
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KMT Intensifier Components
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KMT Intensifier Components
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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
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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
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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
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Pure Waterjet Turnkey System
HP INTENSIFIER
NOZZLE
NOZZLE
ASSEMBLY
ORIFICE
WATERJET
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Optional Water
Treatment System
Waterjet
TOPWORK CONSUMABLES
ON/OFF VALVE
HP WATER
HYDRAULIC OIL
LP WATER
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Electric Motor & Hydraulic
Power Pack
Abrasive Waterjet
TOPWORK CONSUMABLES
ON/OFF VALVE
ABRASIVE
FEEDER
HP WATER
HYD. OIL
LP WATER
NOZZLE
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Electric Motor & Hydraulic
Power Pack
Abrasive
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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
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Abrasive
What is abrasive?
What is mesh size?
What type of abrasive is common?
What is the pricing of abrasive?
Is abrasive recyclable?
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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
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Dynamic Waterjet vs. Standard Waterjet
Very Expensive
High Maintenance
Software issues
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Sizing
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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
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
0.014
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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
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Waterjet Advantages
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Why Waterjet?
Cold Cutting Process
No heat affected zone
No distortion or mechanical stresses
No dross or melting
No fumes, environmentally friendly
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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
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Why Waterjet?
Versatile and Flexible Process
Metals & exotic materials such as Titanium
Highly reflective, thermal conductive materials & polished
materials. Aluminum, Brass, Copper & Galvanized Steel
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Titanium Alloy..
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Brass.. SS.. Aluminum..
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Why Waterjet?
Versatile and Flexible Process
Marble, granite, ceramic tiles & glass
Fiberglass, composites & laminates
Etc….
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Stone.. Glass..
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Waterjet Parameters
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Key Parameters?
Operating pressure
Abrasive: flow rate, type & mesh size
Standoff distance
Cut rate; AWJ a single parameter process
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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
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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
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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
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Edge Quality
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Edge Quality
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Facts about Waterjet?
Optimum cut rate is not maximum cut rate
Generally, AWJ is NOT linear process
AWJ is messy and aggressive process
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Waterjet vs. Others
AWJ
EDM
Laser
Plasma
Gas
Thickness
+
++
-
++
++
Cut Rate
-
--
++
++
+
Surface Finish
++
++
+
-
--
Heat Affected Zone
++
++
-
-
--
Environment Safety
++
--
--
--
--
Material Flexibility
++
-
+
--
--
Secondary Operation
+
++
+
-
--
Operation Cost
-
+
-
+
++
100%
60%
200%
80%
40%
Capital Investment
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Motion Equipment
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XY Tables: Mechanics
Belt Drives +/- 0.010”
Rack & Pinion +/- 0.005”
Ball Screw (Ground/Rolled) +/- 0.003”
Linear Drives (High Speed New Technology)
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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
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Motion Precision
Positional Accuracy
– Per foot or per axis
– Linear per single axis
– Dynamic per dual axis
Repeatability
Tolerance (applied only to finished part)
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XY Motion Configuration
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XYZ Motion Configuration
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Waterjet Practicalities
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Feasibility Questions
Material WJ or AWJ
Parts Small vs. Large
Existing Method & Process
Material Stacking
Justification & Why WJ
Sheet Metals
Primary/Secondary Operation
Loading/Unloading
Cycle Time Concern
Production, Dedicated or Job
Shop
Programming Method
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# of Shifts
Feasibility Questions
Pump Capacity, # Cutting
Heads
Pump Location
Part Tolerance
Sheet Sizes
Water Quality
Tank/Bed Type
Abrasive Reclamation
Abrasive Type & Mesh Size
Zero Discharge Closed Loop
System
Site Planning
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Application Limitations & Practical Considerations
Line Speed
Extrusions
Material Support & Handling
Castings
Automation & Fixtures
Moisture Retention
Wafers & Shim Stock
Ceramics & Carbides
Gumminess
Abrasive Migration
Staining
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Microscopic Abrasive
Adhesion
Non-Compelling Application
Extrusions
Layered non-homogeneous material
Tempered Glass
Tubes
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Terminology
Burr
Kerf
Delamination
Striations
Frosting
Rooster Tail/ Stream Lag
Taper
Splash Back
Fraying
Corners & Curves
Frost Piercing
Practical Thickness &
Limitations
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Supply Water Quality
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Water Quality Standards
MINIMU
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
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
CATEGORY
pH (SU)
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