To address these concerns, “waterjet” technology has emerged as a promising solution. By utilizing only water and abrasive material for processing, waterjet eliminates the need for cutting oil and minimizes the generation of harmful dust. This eco-friendly approach makes waterjet an attractive alternative for environmentally conscious industries.
In this article, we will look into the waterjet processing technology, exploring how it works as well as how it can be used for cutting workpieces with water and abrasive material. We will also discuss the various types of processing methods available and give you helpful insights into selecting the right processing machine and manufacturer for your needs.
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Features of Water Jet Technology
Water jets cut materials like metals and plastics by propelling water at high pressure. Unlike conventional cutting methods, it eliminates the need for various tools and allows for processing and cutting multiple kinds of materials without heat generation.
Because of this ability, water jet cutting has become regarded as an exceptionally eco-friendly technique. Water jet processing can handle both soft and hard materials primarily using only water. Its applications extend beyond automotive and aerospace part production and even finds specialized use in fields such as food and medicine.
Principles and Processing Conditions for Water Jet Cutting
When water is expelled at ultra-high pressure, it creates a high-speed water jet ranging from tens to hundreds of meters per second. Particularly at the nozzle tip, the dynamic pressure is exceptionally high, capable of eroding and removing material from the target object’s surface. A water jet machine utilizes this principle for cutting.While water alone is suitable for processing soft materials like wood and resin, harder materials such as metals and ceramics require the addition of abrasive particles like garnet to the water stream for effective cutting. This method resembles grinding with a stone rather than conventional cutting with a blade.
Indicators for machining with water pressure
When processing with water, the following pressure is used as an indicator.- 100MPa or less: cutting, cleaning, polishing, etc. of soft materials
- 100-300MPa: Cutting, cleaning, polishing, etc. of hard materials such as metals and ceramics
- 300-600MPa: Destruction, crushing, cleaning of buildings made of concrete, asphalt, etc.
The water pressure of the water jet processing machines currently on sale is approximately 350 to 400 MPa. This jet can cut and process most materials.
However, it is not compatible with brittle materials (especially thin glass) that can break when subjected to impact.
Depending on the material, a certain level of thickness is required, so check this before processing.
Structure of water jet
There are mainly three parts that make up a water jet processing machine.- Ultra-high pressure water generator: A device that generates water at an ultra-high pressure. There are plunger type and intensifier type
- Processing nozzle: A part that sprays water, typically a small diameter nozzle with a diameter of 0.1 to 0.3 mm
- Abrasive supply device: A device that mixes abrasive with water, used in abrasive water jet method
A multi-axis processing machine requires a control system in addition to the main body of the processing machine, such as the table and multi-axis cutting head list.
3 types of water jets, features, advantages and disadvantages
There are various types of water jet processing, and they can be divided into applications for cutting and processing materials and applications for destroying objects. Here, we will discuss the types of water jets and the advantages and disadvantages of each.
Characteristics of pure water jet processing
Pure water jet machining is a machining method that cuts a workpiece using only a high-pressure jet of water.Suitable for cutting soft materials such as gasket materials, urethane materials, and resins. It can also be actively used for processing shims and liners. It is also widely used in food processing and medical industries.
Advantages of pure water jet processing
The advantage is that it is environmentally friendly as it is processed using only water. Since no heat is generated during processing, there is no need to worry about the work being deformed due to heat. Furthermore, the Pure Water Jet uses only water, making it easy to maintain and has low running costs.Benefits of pure water jet processing
- Eco-friendly
- Workpiece does not deform due to heat
- High maintainability
- Low running costs
Disadvantages of pure water jet processing
Even with high-pressure water, it is difficult to process hard materials such as metal. To process it, you need to switch to “abrasive waterjet processing”, which will be described later. Also, materials that dissolve in water will dissolve and disappear.Disadvantages of pure water jet processing
- Difficult to process hard materials
- Not suitable for materials that dissolve in water
Characteristics of abrasive waterjet processing
Abrasive water jet processing is a processing method that mixes abrasive material with water to cut the workpiece.It has high cutting capacity and can cut hard materials such as metals and ceramics. It is also actively being used to process new materials for automobile parts and aircraft.
Advantages of abrasive waterjet processing
Since it uses water and abrasives, it has the advantage of being able to process hard materials such as metals. By adjusting conditions such as the amount of water and abrasive, and the jetting pressure and speed, it is possible to cut regardless of thickness or hardness. No dust during processing.Also, like pure water jet machining, no tool friction heat is generated. Thermal deformation of the workpiece can be minimized.
Summary of the benefits of abrasive water jet processing
- Can process hard materials such as metal
- No dust generated during processing
- Thermal deformation of the workpiece can be minimized
Disadvantages of abrasive waterjet processing
Compared to Pure Water Jet, it requires specialized equipment such as an abrasive supply device, so the initial installation cost is higher. Additionally, after processing, it is necessary to separate, collect, and process the abrasive material, which may complicate work efficiency.Care must also be taken when machining hard materials. When machining thick-walled workpieces, more abrasive materials are used and the machining time is longer. In some cases, the cost may be higher than processing methods such as laser or plasma.
Additionally, the waterjet spray spreads in a tapered shape from the nozzle tip. When machining thick workpieces, care must be taken as the machined surface may become tapered depending on the conditions.
Summary of disadvantages of abrasive water jet processing
- High implementation cost
- Work is complicated
- Costs may be high
Characteristics of hydrodemolition processing
Although it is different from the processing of resins, foods, metals, etc., a water jet technology called hydrodemolition is also famous.A method of destroying buildings made of concrete, asphalt, etc. using high-pressure jets of water. It is used at construction sites and in rescue operations during disasters.
Advantages of hydrodemolition processing
Water seeps into the deteriorated concrete. Its unique feature is that it can only destroy old concrete by increasing the internal pressure.With conventional hydraulic breakers, strong vibrations are transmitted throughout the concrete, making it impossible to break only old concrete. Therefore, it can be said that hydrodemolition allows efficient “cutting”.
Furthermore, the water and concrete mixture can be easily recovered and reused, leading to lower processing costs.
Benefits of hydrodemolition processing
- Efficient “chipping” is possible
- Reducing processing costs
Disadvantages of hydrodemolition processing
In general, the processing speed is slower than other destruction methods using heavy machinery. Although it is specialized in destroying concrete, it is difficult to cut reinforcing bars, so we must consider other methods.Also, destruction by hydrodemolition uses a lot of water. Care must be taken in water supply and drainage management.
Disadvantages of hydrodemolition processing
- Slow machining speed
- Difficult to cut reinforcing bars
- Uses a lot of water
Four comparison points | How to choose a water jet
Although the principle is different, there is no big difference from selecting a machining machine.
However, there are also selection items specific to water jets.
Here, we will introduce the points you should compare when introducing a water jet processing machine.
- Output method of ultra-high pressure water generator
- Work material
- Setable work size
- Nozzle range of motion
Output method of ultra-high pressure water generator
There are two types of ultra-high pressure water generators: servo motor driven type and hydraulic intensifier type. Both can raise water pressure to around 600MPa, but the hydraulic type can generate greater force. It has a large discharge volume and can be operated continuously for a long time.Workpiece material
The required units are different depending on the material of the workpiece to be processed, soft or hard, so please be careful when purchasing. For hard materials such as metal, a separate unit is required as abrasives are mixed in.Setable work size
The size of workpieces that can be set on a processing machine is also determined. Please consider the size of the processing machine according to the purpose of use.Nozzle range of motion
Processing machines that can control the processing nozzle at the tip using multiple axes have great advantages in terms of accuracy, in addition to three-dimensional processing. The angle at which the nozzle swings varies depending on the processing machine, so be sure to check it carefully.Although it takes some practice to set up a machining program, machining can proceed with one set of workpieces, which gives a different sense of security in terms of accuracy. In particular, the accuracy is inferior when compared to cutting, so it may be worth considering if you want to maximize accuracy.
Precautions and installation location when installing water jet
Due to the nature of waterjet processing, water may splash. If wood tiles are used in the installation location, they will rot, which is not good for both strength and hygiene. Please install it in a suitable place.Manufacturer that manufactures water jets
We will introduce six manufacturers that manufacture water jet processing machines.
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Sugino Machine
We are the largest manufacturer of water jet processing machines in Japan, and handle a variety of fields other than water jets, including inspection and maintenance equipment. We have many bases in Japan and overseas, and are active in a variety of industries including automobiles, aircraft, pharmaceuticals/cosmetics, and food.Nissin Kiko
The company has many offices in Japan and maintains and manages production equipment and infrastructure, but also develops, manufactures, and sells water jet equipment.The water jet equipment series “Ecomaster” we sell is equipped with a plunger type pump and achieves water pressure of over 245MPa. Capable of cutting many materials.
Flow Japan
A major company that has delivered over 130 million water jet systems to over 100 countries around the world. This is an overseas manufacturer founded in 1974, with its domestic headquarters in Shibuya, Tokyo.It is said that you can order the most suitable water jet processing machine from over 1,000 combinations. It can be customized to suit your needs, so you can implement it appropriately.
Shibuya Kogyo
Shibuya Kogyo, which handles a wide range of businesses including bottling systems and packaging systems, also sells water jets. The number of simultaneous control axes is 3, which is controlled by an AC servo motor, enabling high-precision machining.Comnet
Comnet Co., Ltd. is a CAD software development company established in 1991. Furthermore, we are the sole distributor of the water jet “WAZER” used in workshops and research and development.“WAZER” is touted to be the world’s first compact processing machine, and is not only easy to use, but also about 1/10th the price.
Lezak
Lezac is a cutting die manufacturing company and has developed the water cutter “Aquamaster AM-I” using its proprietary technology.We specialize in cutting sponge rubber, but we can also process plywood boards with a thickness of about 9mm. The cutting surface is vertical, allowing for extremely fine processing.
Waterjet, an eco-friendly processing machine that helps achieve SDGs
With normal processing machines, it is difficult to process without using cutting oil. Additionally, it requires a variety of tools, and there are concerns about distortion and deformation due to the heat during cutting.However, water jets do not require a variety of tools. It can be called a next-generation processing machine because it can process using only water. In order to achieve the SDGs goals, we would like to actively introduce them.
If you are looking to invest in your own pilates machine, please contact us
Are you looking to invest in your own pilates machine, it is important to be aware of the choices that are available to you. Please feel free to contact us if you have any concerns.We will consider the differences between each product and company and suggest the company that best suits your purpose.
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