Basic Knowledge of CNC Waterjet Cutter(1)

 *What are the characteristics and advantages of NC water jet cutter?

 

*What kind of accuracy can the CNC water jet cutter achieve?

 

*What is the maximum thickness of the CNC water jet cutter?

 

*What is the working principle of a high-pressure pump (high-pressure generator)?

 

*What factors affect the efficiency of the CNC water jet cutter?

 

*How to choose a good water jet cutting machine?

 

*How much is the cost of the CNC water jet cutting machine?

 

*What are the common faults of NC water jet cutter and how to eliminate them? Wait a minute... I'll explain them one by one.

 

1. What is the CNC water jet cutter?

CNC water jet cutter is a plane cutting machine which combines the ultra-high pressure water jet generator and two-dimensional NC machining platform. It can raise the pressure of water flow to high enough (above 200MPa) to make water flow have great kinetic energy. It can penetrate the chemical fiber, wood, leather, rubber, etc. Mixing with a certain proportion of abrasive in high-speed water flow can penetrate almost all hard materials, such as ceramics, stone, glass, metal, and alloy. Under the guidance of the two-dimensional NC machining platform, machining can be started or finished at any position of the material, and moving at an appropriate speed according to the set trajectory, so as to realize the plane cutting processing of any figure.

 

2. What are the characteristics and advantages of the CNC water jet cutter?

Compared with the traditional "hot" cutting technology, the ultra-high pressure water jet cutting machine is a "cold" cutting technology, which takes water as cutting medium. It has the following functions and advantages:

 

1. There is no thermal deformation during cutting, which avoids the physical and chemical changes of materials;

 

2. It is widely used in the cutting of various materials and has the reputation of "universal cutting machine";

 

3. The incision is smooth and smooth without burr, so it is generally unnecessary to reprocess;

 

4. Controlled by the CNC system, high cutting accuracy;

 

5. The cutting seam is less than 1.2mm, which is convenient for nesting cutting and saves materials;

 

6. The processing process will not produce waste that pollutes the environment.

 

Numerical control water jet cutter is an ideal or only way to process materials that are difficult to cut by other methods, such as kevler, titanium alloy, and various composite materials.

 

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Basic Knowledge of CNC Waterjet Cutter (2)

3. What kind of accuracy can the CNC water jet cutter achieve?

Strictly speaking, although the CNC waterjet cutter can cut more accurately than the flame and plasma cutting machine, it is not a precision machining tool, and it should not be able to mark the accuracy. When cutting sheet metal less than 10 mm, the cutting speed and compensation should be properly controlled, and the error can be + - 0.1 mm.



4. What is the maximum thickness of the CNC water jet cutter?

Because the target distance of the water jet is uncertain or changeable, the maximum cutting thickness of the CNC water jet cutter is not well defined. It is reasonable for the bold to say 400 mm and 500 mm, and the conservative to say within 100 mm. The current CNC water jet cutter generally has a flow rate of 2-3 liters and a working pressure of 200-380 MPa. The jet passes through the air resistance, and its energy decays rapidly. When it reaches 400 or 500 mm, it basically drifts away with the wind and has no striking force.







For general application, it is recommended that the thickness of cutting metal plate should not exceed 100 mm, and that of foam material such as sponge should not exceed 300 mm.



5. What is the working principle of a high-pressure pump (high-pressure generator)?

Working principle of the oil passage part:



The motor drives the oil pump to draw out the hydraulic oil from the oil tank and transmit it to the oil pressure pipeline through the one-way valve. At this time, the oil circuit is divided into three channels, one is connected with accumulator and pressure gauge, the pressure gauge shows oil pressure, the accumulator can stabilize oil pressure, the second circuit is connected with the directional valve, the other part is connected with overflow valve. When the hot water jet button is not pressed, the hydraulic oil from the oil pump directly flows back to the oil tank through the overflow valve, water-cooled cooler and oil return filter, and a small amount of hydraulic oil enters the oil chamber of the supercharger through the reversing valve, which is not enough to push the oil piston to change direction or change direction slowly; when the boiling water jet button is pressed, the relief valve is closed, and the hydraulic oil enters the oil chamber of the supercharger through the reversing valve. At the same time, the hydraulic oil on the other side of the oil piston is pushed out of the oil cylinder and flows back to the oil tank through the water-cooled cooler and oil return filter. When the oil piston is pushed to the end of the oil cylinder, it collides with the reversing ejector rod, which triggers the reversing valve to generate a reversing signal, so that the hydraulic oil circuit enters from the other end of the oil cylinder and the oil piston returns. At the end of the oil cylinder, the reversing rod is triggered, and the oil piston returns. In this way, the commutator is continuously triggered to reverse the oil circuit, thus forming the reciprocating motion of the supercharger.



Working principle of the waterway



After being filtered by the filter, the tap water is pressurized by the water pump and enters into the high-pressure cylinder at both ends of the supercharger. When the oil piston reciprocates, one end of the high-pressure cylinder enters the water through the water inlet check valve, and the water from the other end of the high-pressure cylinder is pushed out and enters the high-pressure pipeline through the water outlet check valve. This action is carried out alternately in the high-pressure cylinders at both ends to form continuous high-pressure water flow. Due to the existence of a supercharger commutation cycle, the pressure of output water flow forms periodic fluctuation. Therefore, the high-pressure water needs to be stabilized by the high-pressure accumulator and transported to the jet head through the high-pressure pipe. A gem nozzle with an aperture of 0.25-0.33mm is installed on the jet head. High-pressure water jet with great kinetic energy is formed under the restriction of gemstone nozzle, which can break through soft materials such as fiber, leather, and rubber. When a certain proportion of abrasive is mixed in the water arrow, the abrasive water jet is formed, which can penetrate any hard material.



Supercharger principle:



When the hydraulic oil acts on the piston, the high-pressure plunger rod connected to the piston pushes out the water in the high-pressure cylinder. According to the law of conservation of energy, assuming that there is no friction loss, the work done by the two is equal. In this case, the oil pressure multiplied by the piston cross-sectional area is equal to the water pressure times the cross-sectional area of the plunger rod, that is, the ratio of water pressure to oil pressure is equal to the ratio of the cross-sectional area of the oil piston and the cross-sectional area of the high-pressure plunger rod. The ratio of the cross-sectional area of the oil piston and the cross-sectional area of the high-pressure plunger rod is called the "pressurization ratio". Since the ratio is fixed, the water pressure can be adjusted by controlling the oil pressure.

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Basic Knowledge of CNC Waterjet Cutter (3)

6. What factors affect the cutting efficiency of the CNC water jet cutter?

There are many factors that affect the cutting efficiency of a CNC water jet cutter, and they influence each other. It mainly includes structure and quality of cutter head, pressure level and fluctuation range of water jet, intact degree of water nozzle, suitability, and quality of abrasive texture and specification, the integrity of sandblasting pipe, etc.



Note the lower the cutting speed, the better the quality of incision.







7. How to choose a good CNC water jet cutting machine?



When Choosing large manufacturers, you need to have a look at the manufacturers on the market with a large number of waterjet cutting machines. Large scale manufacturers are with timely market feedback, timely improvement of production technology. Besides, they are coupled with the scale effect, and the purchasing scale of raw materials is large, which can ensure the quality of raw materials.





The water jet cutting machine is a processing tool, the standard of a good tool is: with high efficiency; it should be durable, that is, with low failure rate; at low cost.





Step 1: to see the cutting efficiency.



Cutting efficiency includes incision quality and cutting speed. One of the characteristics of a CNC water jet cutter is that the lower the cutting speed, the higher the quality of the incision.



Take the same piece of material to several waterjet cutting machine manufacturers to try cutting, and then compare: under the same cutting quality, whose cutting speed is fast; under the same cutting speed, whose incision quality is high. The minimum requirement for cutting is to cut off the material. The cutting speed is a reliable comparison index.



Step 2: compare durability.



The main fault of the high-pressure cutting machine is the water cutter. The performance of water jet cutting machine manufacturers is different from each other.



The quality of high-pressure cylinder, accumulator, high-pressure plunger, one-way valve plug, high-pressure seal, one-way valve, and other parts directly determine the failure rate of water jet cutting machine. The longer the service life of these components, the better the waterjet cutter is. When signing a contract with the manufacturer, it is better to make clear the service life of the main parts and sign a clear life guarantee contract.



Step 3: compare the cost of repair and maintenance.



At present, there is no common standard for water jet cutting machine, and the interchangeability of parts is relatively low. Moreover, the high-pressure parts of a water jet cutting machines are of limited service life. Therefore, the purchase of a water jet cutting machine not only depends on the price of the whole machine but also on the price of accessories. Not only to see the unit price but also to calculate the comprehensive use cost in combination with the service life.



In short, users can ignore the pressure, flow, and accuracy indicators, and just see and hear how to get guaranteed in the contract.\

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The Pressure of CNC Waterjet Cutter is Increasing

In the past five years, CNC waterjet cutter technology has developed rapidly, from a unique metal cutting method to a reliable cutting tool, which can be seen in many sheet metal processing workshops all over the world. In the past few years, the rise of this technology has left a deep impression on people.



Most of the water cutting equipment manufacturers and users agree that any equipment that can generate 55000-65000 psi pressure can represent the actual level of water cutting work scattered in various processing workshops. At the IMTS 2008 International Machine Tool Expo, the pressure generated by the giant CNC water jet cutter equipment is 60% higher than that of the largest cutting equipment in the past.



As water cutting has become the mainstream of processing technology, people will focus on the operation cost of this equipment, rather than just thinking about the application. In the past, people bought this equipment because it was very outstanding and had extraordinary characteristics. It could cut rubber, titanium, stainless steel, and aluminum. But today, people are more focused on the operating costs of this device.



In the aspect of water cutting technology, the higher pressure produced by it can reduce the operation cost continuously.







For example, a high-pressure water cutting technology designed by a company can produce a continuous operating pressure of 87000 psi. The higher the power generated by the abrasive material in the water jet stream, the higher the cutting equipment can cut at a pressure unit of more than 60000 psi. And the amount of abrasive material used can be reduced accordingly because the higher material speed can improve the metal cutting ability.



Due to the cost problem of grinding materials, it is more and more significant to save the number of materials used. Generally speaking, due to the shortage of supply, the use of materials is increasing all over the world. Taking into account the increasing cost of materials in the United States, if the cost of raw materials in the United States is considered to be increasing, then the cost of processing materials will also be increased.



The higher the pressure of the pump, the greater the stress generated by the internal components. The solution to these powerful new system problems is to strengthen the maintenance and maintenance of the pipelines, fasteners, seals, and other internal components of these systems.



In the future, all users who use water cutting technology will get an unexpected benefit. The technology used in these water jet high-pressure cutting equipment will become the common technology used in all kinds of machinery. The long service life of the pipeline and quick connection interface will become the standard, which will help to extend the maintenance interval of water cutting equipment.



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Notes on Slotting Compensation of Water Jet Cutter

When the water jet cutter is cutting, according to the numerical control instruction, the cutting path is the theoretical size, but the actual cutting size will have a little deviation. This is because there is a slit in the cutting process, and the cutting seam is the part of the loss during cutting. Therefore, if the geometric dimension compensation is not carried out, The length direction of the outer contour part of the actual cutting part will be smaller, and the inner contour size will be larger (the gap width between two sides is just different from that of the single side).



For example, if we want to cut a circular workpiece with a diameter of φ 100 mm and a water beam diameter of 1m, then the cutting track of the water jet cutter will be cut according to a circular path with a diameter of φ 101mm (the cutting motion track is the track of the cutting water beam center, and the motion coordinates indicated by the G code generated in the CAD/CAM software are the coordinates of the cutting motion track), rather than the circle of φ 100mm. If the trajectory is φ 100mm, the diameter of the final cut workpiece is only φ 99mm, and the radius of the cutting water beam is smaller than the required diameter of φ 100mm. In order to compensate for the missing cutting radius, in CAD/CAM software, it is necessary to add a cutting radius (if it is a cutting hole, a cutting radius should be subtracted) on the basis of the workpiece size in the CAD/CAM software, which is called radius compensation, so as to finally process the workpiece with the required size.



Five-axis water jet cutter

The following points should be paid attention to when setting the slotting compensation:

1. After the software compensation is set, it is generally not necessary to compensate on the CNC system, otherwise, the compensation repeated size will appear deviation, but if the software compensation is a little worse after cutting, it can be compensated through the CNC system.

2. If it is compensated by the CNC system, the compensation value should be set to zero in the software.

3. If you are not sure how much size should be compensated, you can cut a rectangle on the scrap, measure the actual size and the programmed size, and calculate the required compensation amount.

4. It is difficult for the CNC system to deal with the compensation of small arcs. If the arc is smaller than the compensation radius, it can not be cut out, nor can it be compensated correctly (in theory, the radius becomes negative). In this case, we should consider modifying the part drawing or using software compensation to find problems in time.



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Which Aspects Should be Considered When Choosing Water jet Cutter?

As we all know, water cutting technology has become a particularly common method nowadays, and its own cold state modern processing technology ensures the cutting quality of the equipment, especially in the processing of some metal materials with high thickness, this water cutting technology is undoubtedly recognized as a more ideal processing method. Customers also need to choose reliable water jet products according to their own demands, so as to improve the utilization effect with the help of this kind of water jet equipment.



Which aspects should be considered when choosing a cnc waterjet cutter

1. Working efficiency of water jet cutter

It is self-evident that the primary purpose of the cutting machine is to cut off the material. In general, the cutting speed of different thickness materials must be very different. If you want to start from this angle, the water jet cutting speed can be calculated. And the speed of the water jet cutting material is a key standard.

2. Durability of equipment



Checking the quality of various parts of the equipment, including high-voltage generator and nozzle, directly determines the failure rate of the equipment. Only by carefully measuring the service life of each part of the water cutter, can the service life of each part of the water knife be improved, and the service life of the water knife can be improved.

3. The maintenance cost of equipment



Each part of the CNC water jet cutting machine has its limited service life. When selecting the water cutting machine, we should not only look at the price of the whole machine, but also pay attention to the cost of each small part, and then calculate the cost of the equipment by comprehensive service life.



In short, with the continuous development of the market economy and the continuous progress of science and technology, many new cutting equipment emerge in endlessly, and as a more popular large-scale equipment in the industry, water jet must be more understanding, in order to choose good equipment suitable for their own. Based on the function and various factors of this kind of water jet equipment, a more reliable device with cost performance is selected, so that the operation of this equipment and its deep processing has better execution space, and it can also really take advantage of the advantages of the water cutter material to bring better guarantee for its plate processing and subsequent production.



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Types of Stone Line Processing Machines

There are two kinds of stone line processing machines from the processing products:



1. Processing capacity is not very large; there are many varieties

2. Large processing capacity; with not many shapes; suitable for mass production



stone line processing machine from the mechanical point of view, which machine is suitable for processing output:

1. A small amount of processing, it is recommended to buy a stone line copying machine

2. A large amount of processing, it is recommended to buy automatic stone line machine



Comparison of daily processing output between automatic stone line machine and stone profiling machine:

1. Automatic stone line processing machine daily processing output can reach 200-300 meters (8 hours), good processing effect, no silk, good handle, neat seams, brightness up to 90-120 degrees, no need to wax, no knife, processing speed is fast.

2. The daily processing output of the stone copying machine is about 30-50 meters, which is only rough grinding. It also needs manual polishing, waxing, uneven joints, dark brightness, no glossiness, low output, and high labor cost.

3. The daily processing output of the stone bridge edge grinding machine is about 60-100 meters. Due to the operation of one grinding wheel, the grinding wheel needs to be replaced several times. In this case, the grinding wheel is replaced frequently, which wastes a lot of labor time, and the processing capacity can not be raised. If you want to process fast, you need to buy several more stone bridge edge grinding machines, one for grinding shape, one for rough polishing and one for fine polishing, At least three machines are required to process at the same time. The processing speed is faster when the grinding wheel is not always replaced. In this case, it is better to buy an automatic stone line polishing machine. Moreover, the final processing effect is not as good as that of the automatic stone line processing machine. The output is not as large as that of the automatic stone line processing machine, and several workers are required to operate it, It's cost-effective to buy this kind of machine without buying an automatic stone line processing machine.



Automatic stone line processing machine can be divided into:

1. Stone molding machine

2. Stone polishing machine

3. All in one machine for shaping and polishing stone lines



Stone line shaping machine (for line modeling) can be divided into:

1. 4-head stone line shaping machine

2. 5-Head stone line shaping machine

3. 6-head stone line shaping machine



Stone line shaping and polishing integrated machine can be divided into:

1. 3 + 5 stone line processing machine (3 head shaping, 5 head polishing)

2. 4 + 4 stone line processing machine (4 head shaping, 4 head polishing)

3. 3 + 6 stone line processing machine (3 head shaping, 6 head polishing)

4. 3 + 7 stone line processing machine (3 shaping, 7 polishing)

5. 4 + 6 stone line processing machine (4 shaping, 6 polishing)



Stone line polishing machine (pure polishing) can be divided into:

1. 6-head stone line polishing machine

2. 8-head stone line polishing machine

3. 9-head stone line polishing machine



The automatic stone line polishing line can be divided into:



1. 4 + 8 (12 heads) automatic stone line polishing machine (1 set for 4-head shaping and 1 set for 8-head polishing)

2. 5 + 8 (13 heads) automatic stone line polishing machine (1 set for 5-Head shaping and 1 set for 8-head polishing)

3. 6 + 8 (14 heads) automatic stone line polishing machine (1 set for 6 heads and 1 set for 8 heads polishing)

4. 4 + 6 (10 heads) automatic stone line polishing machine (1 set for 4-head shaping and 1 set for 6-head polishing)

5. 4 + 7 (11 heads) full automatic stone line polishing machine (1 set for 4-head shaping and 1 set for 7-head polishing)



For small stone processing plant, it is suggested to select 8-head (3 + 5) stone line processing machine



For the selection of batch processing stone line: 12 head (4 + 8) stone line processing machine



If processing natural marble lines, it is recommended to use 12 head (4 + 8) automatic stone line processing machine. Because the marble lines are brittle and have cracks, it is necessary to polish the lines by adding glue and polishing them with a polishing machine. In this way, the processing effect will not be affected and the processing speed will be fast.



It is recommended to consult the manufacturer by telephone first to know in detail what kind of material to process, how much to produce per day, and what kind of configuration to choose. This is the most suitable stone processing machine for you.

We are best granite cutting machine manufacturers, if any stone processing equipment /mosaic cutting machine in need,contact us now!